Ko-111-01 Repair Welding+Manual e (20201207)

PART NO.
KO-111-01
REPAIR WELDING MANUAL

URL:http://www.hitachi-kenki.co.jp
KO-111-01
PRINTED IN JAPAN (K) 2019, 09

FORWARD
Forward
If construction machines work under severe conditions for long period, cracks may occur in the structure due to metal
fatigue.
To reduce down time and to extend the life of the machine, it is imperative to check for cracks and to repair as soon as
possible. Repairing cracks by appropriate welding techniques (crack detection, restraint, preheating, gouging, repair
welding, after heating, reinforcement, and finishing) are most important and effective measures.
However, if inadequate repair welding is applied, cracks will develop again in a shorter period of operation than before,
making it difficult to trace the cause of the repeated crack. If appropriate welding techniques are not performed, this will
allow cracks to develop repeatedly.
 This manual describes repair welding for mining machine structures.
 This manual aims to introduce the correct method of repair welding to prevent cracks from developing repeatedly.
 This manual is intended for welders who have completed technical training of welding (American Welding Society
Class 3 or up, or equivalent), Hitachi sales support servicemen and Hitachi Dealer servicemen who are in the position
to supervise repair welding.
 Repair works shall be implemented according to the countermeasures diagram issued by Hitachi; this manual shall be
used as a supplementary reader.
Be sure to thoroughly read this manual for correct repair welding information and procedure.
Information and specifications in this manual are for repair welding purpose only. They may be different from those of
Hitachi construction machinery factory procedures and standards.
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at
any time without notice.
COPYRIGHT ©2019
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
FORWARD
How to Use This Manual

Use this manual as follows:
If there is an individual countermeasure diagram, prioritize its description over this manual.
 When performing repair welding work:

The minimum basic knowledge required for welders and Hitachi sales support servicemen and Hitachi Dealer
servicemen who supervise repair welding at a job site are contained in the following sections.
Before starting repair welding, be sure to read these section. Furthermore, when asking a specific repairer to perform
welding, always recommend to him to read these sections.
CAUTION DON’T: DON’T:

FUNDAM EXAMPLES
ENTALS
yellow pages blue blue
 When any questions on the method or details of repair welding arise:

 When training welders:
The answers to the questions or useful information on the above items are contained in the following sections. Hitachi
servicemen who are in position to supervise welding should have this information in advance.
TOOLS & INSPECTION RESTRAIN PREHEA GOUGING REPAIR REINFOR FINISHING APPENDIX
AUXILIARY OF CRACKS ING TING WELDING CEMENT
EQUIPMENT
SECTION AND GROUP
CONTENTS Group 1 SAFETY
Group 2 DON’T’S: FUNDAMENTALS
Group 3 DON’T’S: EXAMPLES
Group 4 TOOLS & AUXILIARY EQUIPMENT
Group 5 INSPECTION OF CRACKS
Group 6 RESTRAINING
Group 7 PREHEATING
Group 8 GOUGING
Group 9 REPAIR WELDING
Group 10 REINFORCEMENT
Group 11 FINISHING
Group 12 APPENDIX
All information, illustrations and

specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT ©2019
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
(Blank)
SECTION 1
SAFETY
– CONTENTS –
1-1. Safety......................................................................................1-1
(Blank)
SECTION 1 SAFETY
1-1. Safety
Follow Safety Instructions
 Safety first
 Allow only trained, qualified, authorized personnel to
perform repair welding.
(American Welding Society Class 3 or up, or equivalent)
 Carefully read and follow the instructions in this manual.
Also, read the safety section of the operator's manual
before performing any welding work.
 Be sure to follow your local safety regulations.
SA-003
Safety Precautions for Repair Welding Work

 Prepare for emergencies
 Be prepared for an accident or a fire.
 Wear protective clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Use tools and equipments appropriate for the work to be SA-437

done.
 Makeshift tools, equipements and procedures can create
hazards.
 Be sure to ground the welding machine. Be sure that
the welding machine is equipped with an electric shock
prevention device.
 Protect against hazardous light rays and hot metal splatters

 Hazardous light rays and hot metal splatters are produced
when arc welding is performed. To protect your body
from these hazards, wear a welding apron and shin
guards. Also, be sure to use a face shield to protect your SA-438
eyes and face.
 Protect against noise

 Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against constant or
uncomfortably loud noises.
SA-024
 Protect against flying debris
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Wear goggles or safety glasses when under condition
with flying of metal, when working with grinder, or when
removing or installing pins.
SA-022
1-1
SECTION 1 SAFETY
Precautions for Welding and Heating

 Hazardous fume can be generated when paint is heated by
welding or soldering.
Do all such work outside or in a well-ventilated area.
 Avoid potentially toxic fumes and dust.
 Remove paint before welding or heating

 When removing paint with a grinder, wear an approved
respirator to prevent inhalation of dust.
 If you use solvent or paint stripper, remove combustible
materials with soap and water before welding. SA-029
 Remove solvent or paint stripper containers and other
flammable material from area.
 Allow fumes to disperse at least 15 minutes before
welding or heating.
 When welding or heating in an enclosed area, be sure to

provide a ventilator and wear a dust respirator.
 Pressurized pipes and hoses can be accidentally bursted

when heated directly. Remove hoses from splatter area if
possible, or cover hoses with a fire protection cover.
 Before starting to weld or using a torch, thoroughly clean

or remove any spilled or stuck grease, oil, paint or any other
flammables from the area. If any flammables cannot be
removed, be sure to cover them with a fire protection cover.
Cautions to be Taken While Welding and Heating

 When heating a hydraulic component, piping, or the vicinity
thereof may generate flammable vapors or sprays that may
ignite.
 Avoid welding or heating by a torch around the hydraulic

components or lines.
 After completion of welding and heating work always check

smoke or any other indication of fire.
 If the gas burner burns incompletely during preheating,

unburned gas may accumulate in the enclosed space (in the
boom or arm) and an explosion may occur. Inspect the gas
burner before work to ensure that there are no phenomena
such as incomplete combustion, uneven flames, or difficult SA-030
ignition.
1-2
SECTION 1 SAFETY
Use Handholds and Steps

 Falling is one of the major causes of personal injury.
 When getting on and off the machine, always maintain a
three-point contact with the steps and handrails, and
face the machine.
 Do NOT use any controls as handholds when getting on
or off the machine.
 Never jump on or off the machine.
Never mount or dismount during a moving machine.
 Be careful of slippery conditions on platforms, steps, and
handrails when getting on or off the machine. Also, repair
any damaged parts and retighten any loose bolts. SA-439
 Do NOT get on and off the machine when tools in hand.
Precautions for Machine Operation

 Never lubricate or service the machine while it is moving.
 If a maintenance procedure must be performed with the

engine running, do NOT leave the machine unattended.
 Take precautions when operating the machine

 Be sure to start the engine only while operator seated in
the operator's seat.
 Always be alert for bystanders moving into the work area.
Use the horn or other signal to warn bystanders before
starting the engine and before moving the machine. SA-007
 Machines experiencing trouble may move in unexpected
ways. Be sure to operate the machine slowly while
observing machine movements closely.
 Use a signal person when backing up, if your view is
obstructed. Always keep the signal person in view.
 Learn the meaning of all flags, signs, and markings used
on the job, and confirm who has the responsibility for
signaling.
 Be sure to remain seated in the operator's seat while

operating the machine.
1-3
SECTION 1 SAFETY
Practice Safe Repair Welding

 Must be understand about the repair welding procedure
before doing work. Also, make sure that your coworkers
understand the repair procedures as well.
 Prepare and clean the work area.

 Select a firm, level surface, protected from wind and rain.
 When working under the machine is unavoidable, bring
the machine to a repair shop where an appropriate pit is
provided. When an appropriate pit can not be provided,
dig a hole large enough for use as a maintenance pit.
Never attempt to work under the machine when arm and
boom are raised.
 Before starting any service work, clean the work area.
Remove any objects that may be a safety hazard to the
service personnel or bystanders.
 Remove any buidup of grease, oil, paints, or debris.
SA-028
 Park the machine safely.
 Beware of exhaust fumes.

Engine exhaust fumes can cause sickness or death.
 If you must operate inside a building, be sure there is
adequate ventilation.
 Either use an exhaust pipe extension to remove the
exhaust fumes, or open doors and windows to bring
enough outside air into the area.
 Illuminate work area safely.

 Illuminate your work area adequately but safely.
 Use a portable safely light for working inside or under the SA-033
machine.
 Make sure that the bulb is enclosed by a wire cage. The
hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
 Allow the engine and the hydraulic oil to cool before

starting any service work.
 Disconnect the battery ground cable (-) before welding on

the machine. Or set the battery disconnect switch to the
“OFF” position.
SA-016
SA-037
1-4
SECTION 2
DON’T’S: FUNDAMENTALS
– CONTENTS –
2-1. Don’t’s: Fundamentals......................................................2-1
(Blank)
SECTION 2 DON'T'S: FUNDAMENTALS
2-1. Don't's: Fundamentals

Preparations
 DO NOT perform gouging work without confirming the
number, size, and location of cracks/defects.
If the crack/defect is not grasped clearly in advance, the
defect-free part may be gouge/removed or the defective
part may not be removed because the sufficient gouging
depth may not be obtained in order to remove crack/
defects.
 DO NOT perform repair welding work without recording
all confirmed data.
If there is no record, the third party does not know where
and how it was repaired. Therefore, the cause cannot be
grasped when the crack recurs near the repair site.
 DO NOT perform repair welding without thoroughly
understanding the contents of corrective and/or
preventive measure drawings.
The strength may be decreased if the reinforcement plate
is incorrectly welded or if the required grind finishing is
omitted.
 DO NOT perform repair welding without thoroughly
understanding corrective and/or preventive measure
procedure (steps).
If the repair procedure is wrong, welding inside the box-
shaped structure, attaching ribs, removing cracks, etc.
may be insufficient, or work may not be performed.
 DO NOT let anyone without a proper welding certificate
(American Welding Society Class 3 or up, or equivalent)
perform repair welding work.
If an unqualified person performs welding work,
incomplete fusion or poor penetration which causes
decrease in strength may result.
 DO NOT perform repair welding work in rain or falling
snow.
Electrocution may result. Also, blowholes or cracks may
result.
 DO NOT perform repair welding on surfaces to which
lubricants, mud, and/or paint are attached.
A fire may result. Also, blowholes may be induced.
Moreover, when removing cracks by gouging, the cracks
may not be completely removed as the depths and
directions of cracks may not be correctly located.
2-1
Restraining
 DO NOT work without restraint fixture where restraint
fixture is required.
Heat is applied when gouging or welding. When the heat
falls, the base material shrinks, causing distortion (falling
down and twisting).
 DO NOT use restraints fixture that cannot withstand
deformation.
If the restraint fixture material is weak, the restraint fixture
material itself will be deformed and useless.
 DO NOT weld a restraint fixture to machined surfaces.
If a restraint fixture is welded on a machined surface, the
machined surface must be machined again.
 DO NOT attach restraint fixtures without checking the
dimensions.
If welding is performed without first measuring the
dimensions of the matching parts, the match may not fit;
welding-induced distortion cannot be corrected without
knowing the original dimensions.
 DO NOT apply preheating work without attaching
restraint fixtures.
Similar to the case of welding work, as the temperature
of preheated parts goes down, the preheated parts may
distort.
Preheating
 DO NOT perform welding on high tensile strength steel or
on special steel without preheating it.
Welding without preheating can cause cracks. Preheating
prevents cracks, hardening and embrittlement.
 DO NOT perform welding work when the temperature is
lower than 10 °C (50 °F).
Performing welding when the temperature is lower
than 10 °C (50 °F) may cause a state of rapid heating and
cooling, resulting in cracks around the welded part.
 DO NOT start welding without measuring preheat
temperature.
Low preheat temperature may cause cracks. High preheat
temperature may cause brittling of the base metal which
may result in cracks in the base metal.
 DO NOT heat high tensile strength steel or special steel to
more than 400 °C (752 °F) and rapidly cool it.
Base metal becomes brittle. In some cases, cracks may
develop in a few days.
 DO NOT heat metals to temperatures more than required
and DO NOT expand the heating area.
Base metal becomes brittle and resulting distortion
increases.
2-2
Repair welding
 DO NOT ground far away from the welding part.
For example, do NOT ground at a hydraulic cylinder when
welding on the frame.
As a gap exists between the cylinder tube and the piston,
sparks will be generated at the gap, causing damage to
the cylinder.
 DO NOT use an inappropriate gouging rod.
Relatively large rod diameter compared to the plate
thickness may cause the plate to be penetrated.
 DO NOT use a faulty holder (torch) or gas burner.
Electrocution or burns may result. Also, appropriate
heating or welding cannot be done with it.
 DO NOT perform gouging using a gas burner on high
tensile strength steel or on special steel.
As the temperature excessively rises, base metal becomes
brittle, causing cracks.
 DO NOT perform any gouging without confirming the
thickness of plate first.
If it is penetrated during gouging, a notch will be left if
the back side cannot be welded.
 DO NOT generate arc strikes (sparks) on places other than
the welding part.
Arc strike parts harden. Even after grind finishing, cracks
may appear at the bent areas of plates or rounded areas.
 DO NOT weld the gouged part as it is.
A weld defect occurs inside or becomes brittle. Therefore,
after gouging, grinder finishing must be performed
before welding.
 DO NOT use flux cored wire or coated electrode which is
not dry.
When welding with a damp electrode, especially with
that of low hydrogen type, the weld metal may become
brittle, causing cracks as well as other failures, such as
blowholes.
 DO NOT use any electrodes or welding wires except for
those specified.
Desired strength may not be obtained. Also,
inappropriate bead forms may result, causing cracks.
 DO NOT weld with defects.
Cracks will appear in a short time after completion of
repair welding.
 DO NOT weld on high tensile strength steel or on special
steel, surpassing interpass temperature.
Base metal around welded parts becomes brittle. Also,
it may cause distortion to increase. Keep interpass
temperature higher than preheating temperature and
lower than 400 °C (752 °F).
 DO NOT rapidly cool (or quench) high tensile strength
steel or special steel.
The steel may become brittle. For this reason, toughness
may decrease, eventually leading to breakage.
2-3
 DO NOT perform welding work without taking into
account crack propagation (progression).
If no appropriate corrective measure is taken, cracks may
not be completely removed, or cracks may propagate.
 DO NOT perform welding heavily on one side when
performing welding on both back and front surfaces or
performing left and right symmetrical welding.
If the work is done unevenly, excessive distortion will
result.
 DO NOT weld the gas cut surface without grind finishing.
Poor penetration caused by notches on cut surface
will result. Also, weld defect caused by slag inclusion
may result.
 DO NOT close manholes without first confirming and
recording what was done inside of a box type structure.
Required welding inside or grind finishing might have
been omitted.
Straightening
 DO NOT perform straightening with welding fixtures
removed.
Amount of distortion may increase and distortion
directions may become multi-dimensional, causing
straightening to become very difficult.
 DO NOT heat high tensile strength steel or special steel to
more than 400 °C (752 °F) and rapidly cool it.
Base metal becomes brittle. In some cases, cracks may
develop in a few days.
 DO NOT heat metals to temperatures more than required
and DO NOT expand the heating area.
Base metal becomes brittle and resulting distortion to be
increased.
 DO NOT perform straightening on one side only.
Amount of distortion increases and distortion directions
may become multi-dimentsonal.
 DO NOT heat and then rapidly cool machined surfaces.
Distortion will develop on machined surfaces.
2-4
Reinforcement
 DO NOT add reinforcing plate carelessly.
If a reinforcing plate is carelessly added, it may inversely
increase stress concentration, leading to the occurrence
of new cracks.
Finishing
 DO NOT finish rougher than the standard.
If the finished surface is rough, or if there is a notch due
to grinder finish in the surface, stress will concentrate and
break.
 DO NOT omit grind finishing on any specified areas.
Although weld bead or ends of bead may look smooth
and flat, there always are undercuts and/or overlaps,
causing stress concentration.
 DO NOT leave any notches on finished surfaces.
Even a notch on a smooth finished surface causes stress
concentration on it, eventually leading to breakage. Be
careful not to leave any notches on finished surfaces.
Especially check toe of bead.
 DO NOT grind finish any machined surfaces.
Precise dimensions cannot be obtained by grinding. For
this reason, oil leakage or excessive wear may result.
2-5
MEMO
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
2-6
SECTION 3
DON’T’S: EXAMPLES
– CONTENTS –
3-1. Don’t’s: Examples................................................................3-1
(Blank)
SECTION 3 DON’T’S: EXAMPLES
3-1. Don’t’s: Examples [Vise-Installed Example]

Base Metal Vise
 DO NOT leave any gap between the backing plate and
Less than
base metal. 0.5 mm
If any gap is left between them, the weld metal will (20/1 000 in)
melt into the gap, forming a notch that induces stress
concentration, leading to a premature breakage of the
welded part.
Use a holding device, such as a vise, to eliminate gaps. Backing Plate TDC-24
Gap between the backing plate and base metal must be
less than 0.5 mm (20/1 000 in).
RIGHT WRONG
 DO NOT tack-weld ends of the backing plate.
When using a flat-bar-type backing plate, avoid
performing tack welding in the range approx. 40 to 50
mm (1-1/2 to 2 in) from the contacting end, as illustrated.
Tack welding close to the end may cause stress
concentration, leading to premature breakage of the End
welded joint. Maintain Backing Plate
40 to 50 mm (1-1/2 to 2”)
distance TDC-26
Completely
 DO NOT tack-weld the backing plate from the inside. remove the
When installing the backing plate for covering an access RIGHT tack welding WRONG
hole by tack welding, weld the back plate at the weld beads using Base Metal
a grinder Outside
groove, as illustrated. just before
Then, remove the tack welding beads one by one just the regular
before regular welding is performed on the tack welded welding.
part.
Inside
Backing Plate
TDC-25
3-1
 DO NOT let the root gap for backing plate welding be too RIGHT WRONG
wide or too narrow.
Narrow root gap results in incomplete penetration,
leading to bead cracking.
Wide root gap induces stress concentration at the joint.
Backing Plate
Wide Root
Correct Root Gap Gap
4 to 6 mm
(1/8 to 1/4”) Deep Penetration
WRONG
Incomplete
Penetration
Narrow
Root Gap TDC-27
 DO NOT leave any gap between the base metal and the
reinforcing plate.
If any gap is left between them, the reinforcing plate will
not function. Be sure to reduce gap to less than 0.5 mm
(20/1 000 in), as illustrated below.
Wedge
Weld here first

Tack Welding
Tighten with the bolt RF-005 Press the plate using the wedge RF-006
 DO NOT divide reinforcing plates carelessly.

Joining reinforcing plates at stress concentrated places is
a very dangerous practice.
Many premature breakage of the welded joints at stress
concentrated places have been reported.
Be sure to always follow division of reinforcing plates
specified in the countermeasure and/or preventive
measure drawings to perform reinforcing plate additions.
RIGHT Joining plates at stress WRONG

concentrated places
Reinforcing Plates
RF-009
Join reinforcing plates at low fNOTE: Stress concentrated areas in the

stress concentrated places RF-008 above illustrations are for illustrative
purposes only.
3-2
 DO NOT plug-weld any reinforcing plates.
If a reinforcing plate is installed by plug welding, it will RIGHT
NOT function properly.
Anti-Wear
Moreover, it may induce new cracks at plug welded parts. Plate
Use plug welding method only when installing anti-wear
materials.
RW-03-03-002
WRONG
Reinforcing Plate
RW-03-03-003
 DO NOT penetrate through base metal when removing a
through crack by gouging. α
Repair work will be extremely difficult once the base
metal is penetrated by gouging.
Refer to the illustration right to remove through cracks.
t
3 mm (1/8”)
or more
4 mm (5/32”)
or more
10 mm (13/32”)
or more
GA-008
 DO NOT commence grinding without first considering the
lengthwise direction of the crack.
Since notches and scratches that occur in the direction
of grinder disk rotation will cause cracks to recur, finish
them securely so that they do NOT exist.
Grinder-Left
Rings (Lines)
Crack Grinder
SA-006A
3-3
 DO NOT weld plate edges.
In general, plate edges are stress concentrated. For this
reason, notches may be left at stress concentrated places
if plate edges are welded.
Be sure to avoid welding plate edges.
When the restraint material is attached, remove it
completely and finish the surface so that notches and
scratches does not remain after removal.
TDC-55
RIGHT WRONG
Restraint Fixture
Weld
TDC-56
Small Notch Correcting with Grinder

 DO NOT leave any notches on the temporarily tack-
welded spots after tack-welded welding fixtures are
removed.
If any notches remain, stress concentrates on them,
leading to premature breakage.
When notches are small, finish them smoothly using a
grinder. Large Notch Removing with Grinder
For larger notches, remove using a grinder. Then, perform
overlaying and finish using a grinder. A little concaved
finished surface is acceptable, infecting the strength, as
long as it is smooth.
40 to 50 mm
(1-1/2 to 2 in)
Overlaying Finishing with Grinder
TDC-58
WRONG
 DO NOT reinforce using ribs.

When a rib is installed, stress concentration is always
induced in other places.
For this reason, never add ribs unless instructed so in the
countermeasure and/or preventive measure drawings.
RF-013
3-4
 DO NOT lay welding bead perpendicular to the force
applied direction.
Bead laying perpendicular to the force applied direction
acts as a large notch, inducing stress concentration.
RIGHT WRONG
Force Applied Force Applied
Direction Direction To Front Attachment
or
Seat Screw EX-001
 DO NOT leave bump where bead leg length changes.

A large bump will induce stress concentration. Lay bead
WRONG
smoothly without leaving a bump when changing bead
leg length.
Smoothly finish the bead leg changing point with a
grinder as necessary.
Smoothly
RIGHT
SA-007A
2A or more
Bead A
RW-03-01-001
 DO NOT change bead leg length at a corner.

Stress concentration is liable to be induced at corners. Be
sure to avoid changing bead leg length, which induces
more stress concentration, at corners.
RIGHT WRONG
EX-002
3-5
 DO NOT lay weld lines close together.
If weld lines are laid close together, the combined
residual welding stress will make the welded joints and
surroundings brittle.
RIGHT WRONG
100 mm (4”) or more Too close
Bead
EX-003
 DO NOT leave any notches on gas-cut surfaces.

In order to prevent weld defect and poor penetration
from occurring, be sure to smoothly finish gas-cut
surfaces, such as reinforcing plate edges and access hole-
cut surface including its cover, using a grinder.
Gas-Cut Surface
Access Hole
RIGHT WRONG
Grinder-Finished Surface Gas-Cut Surface
EX-004
3-6
SECTION 4
TOOLS & AUXILIARY EQUIPMENT

– CONTENTS –
4-1. Tools & Auxiliary Equipment...........................................4-1
(Blank)
SECTION 4 TOOLS & AUXILIARY EQUIPMENT
4-1. Tools & Auxiliary Equipment

Before starting repair work, sufficiently study and
understand the repair drawings, and select tools and
auxiliary equipment necessary for the work.
Examples are as shown.
1. Preparation
 Movable Scaffold
Footing
 Protectors
Refractory cover for cylinder rod protection
Cover binding wire
Grounding wire
Wind screen Movable scaffold RW-04-01-001
 Crack Report
Crack report form
Repair welding report form
Photo-camera with close-up function
 Fire proof cover and extinguisher
2. Crack Check
 Checking Tool
Ultrasonic flaw detection device
Development solution for liquid penetrant inspection
(Dye check)
 Linear Measure
Tape measure, ruler, etc.
RW-04-01-002
Liquid penetrant inspection solution
 Others
Plate thickness gauge
Cleaning solvent
Shop towel
Illumination
3. Restraining
 Restraining Material and Tools
Material for restraining member (Fixture)
Hydraulic jack
Journal jack
 Linear Measure
Tape measure, ruler, etc.
 Welding machine
Plate thickness gauge RW-04-01-003
4-1
4. Preheating
 Preheating Equipment
Gas torch, gas burner
 Thermometer
Thermal chalk, surface thermometer
5. Gouging
Thermal chalk RW-04-01-004

 Gouging Equipment
Gas torch, scriber, chalk, compasses
 Gouging Machine
Arc-air gouging machine
 Inspection Equipment
Liquid penetrant inspection solution (Dye check)
Ruler
 Exhaust Gas Equipment, Dust Respirator
 Finishing Tool Surface Thermometer (Non-Contact) RW-04-01-008

Pencil grinder (Tungsten carbide cutter)
Angle grinder
 Hard Hat
6. Repair Welding  Hood
 Face Shield
 Dust Respirator
 Welding machine  Earplug
 Apron
Manual welding machine, semi-automatic welding  Leather Gloves
machine, electrode dryer  Shoe Cover
 Safety Shoes
 Slag Removing Tool
Hammer, air chisel, wire brush, etc.
 Exhaust Gas Equipment, Dust Respirator

RW-04-01-009
 Weld Inspection
Ultrasonic flaw detection device Examples of Protective Equipment for Welding Work
Liquid penetrant inspection solution (Dye check)
Bead-leg-length gauge
Ultrasonic flaw detection device RW-04-01-005
4-2
7. Reinforcement
 Reinforcing Plate Fixture

Hydraulic jack, chain block, turnbuckle, lever block,
journal jack
8. Finishing
 Finishing Tool
Pencil grinder (Tungsten carbide cutter)
Straight grinder
Angle grinder
 Painting Tungsten carbide cutter RW-04-01-006

Touch-up paint
 Others
R gauge, template, compressor
Straight grinder RW-04-01-007
4-3
MEMO
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
4-4
SECTION 5
INSPECTION OF CRACKS
– CONTENTS –
5-1. Importance of Inspection................................................5-1
5-2. Record and Report.............................................................5-2
5-3. Visual Inspection.................................................................5-4
5-4. Liquid Penetrant Inspection...........................................5-5
5-5. Ultrasonic Flaw Detection Method..............................5-7
5-6. Magnetic Powder Method..............................................5-8
(Blank)
SECTION 5 INSPECTION OF CRACKS
5-1. Importance of Inspection

Inspection of cracks on a structure is important to quickly
trace the cause of cracks, to decide corrective measures to be
taken, and to make the proper preparation for the repair work.
Perform the inspection of the crack on the following points.
 Location(s) of the cracked section(s)

 Number(s) and length of the crack(s)
 Depth of the crack(s) after being gouged
Referring to the above information, decide the corrective

measure to be taken, the procedure of the repair work, time
schedule, and prepare necessary equipment and tools.
RW-05-01-001
IMPORTANT: Incorrect information will not only obstruct

making a plan of the corrective measures but also
lead to improper repair work, leading to earlier
development of cracks than before performing the
Crack
repair work.
RW-05-01-002
5-1
5-2. Record and Report

Make the record and report of cracks as follows:
1. Information on Machine Operation

Use “Crack Report Form” in the section 12 “Appendix”.
2. Information on Crack
 Be sure to indicate the location of any cracks using
“Drawing”, “Parts Catalog”, or “Visual Check List”.
 Be sure to indicate the distance from a reference position
to the crack and the crack length to correctly locate the
cracked position, as illustrated to the right (L1, L2, L3, and
L4).
 Check and report if more than one of the base metals are
cracked.
 In case that crack (s) develop in the weld joint, make it
clear that either the toe of weld is cracked or the weld
bead is, as shown by (a), (b), and (c) in the table to the
below.
 In case that crack (s) have developed, check the starting
point of the crack and be sure to report the starting point.
 Report the weld appearance at the cracked section
regarding if any weld defects such as short-bead-leg
length, undercut, overlap, and blowhole on the weld
bead surface are noticeable.
 If a crack has developed on a box type section, report if
the crack was started from the outer surface or from the
inner surface. However, when such judgement is difficult,
avoid making a hasty conclusion. Be sure to report only
the points actually recognized.
 Be sure to report the serial No. of the front attachment.
(The stamp location of the serial No. is illustrated below.)
*Crack is developed from toe (C) of the bead.

*The appearance of the bead has no fault. No overlap is found.
Crack in toe (C)

of the bead.
L2
L1
Manufacturing
No. (stamped).
L3 * Crack has developed in toe (a) of the bead.

* The appearance of the bead has no fault. No overlap is
L4 recognized.
No crack.
Crack in toe (a)

of the bead.
RW-05-02-001E
5-2
3. Photograph
Be sure to take three kinds of photographs of the crack as
illustrated below.
(1) Photograph of the entire cracked section.

(Cracked base metal must be clearly indicated.)
(2) Detailed photograph of the crack indicating the crack
length, the starting point of the crack, and the weld
bead form.
(3) Photograph showing how temporary or final repair
was made.
Take the photograph after marking the position
such as "Right", "Left", "Upside", "Downside"
using chalk or paint.
Arm
bulkhead
Bottom
plate Rib
Indicate the crack using chalk or paint.
Crack
Preferable to take the photograph

with a ruler.
RW-05-02-002E
5-3
5-3. Visual Inspection

When performing the visual inspection, sufficiently lighten
and check the following points:
 Separation of the paint

 Appearance change on the base metal
 Place (s) covered with fine dust
 Oil-oozed place
In addition, it is required to trace the cause of the cracks by

checking the direction of load to be applied.
5-4
5-4. Liquid Penetrant Inspection

Liquid penetrant inspection is a method for making it easy
to visually check cracks appearing on the surface. Follow the
procedure below.
IMPORTANT: Since the liquid used in the liquid penetrant

inspection is flammable, the vaporized liquid may be
ignited in a closed space (inside the boom or inside
the arm). Provide sufficient ventilation when handling
liquids.
1. Preparation of necessary equipment

(1) Cleaning Solvent
(2) Penetrant
(3) Developer
(4) Wast Cloth Cleaning Solvent Penetrant Developer
(5) Rubber Gloves RW-05-04-001
(6) Safety Glasses
2. Cleaning the Inspection Surface

(1) Spray cleaner on the inspection surface to remove oil
and grease.
(2) Sufficiently dry the inspection surface.
Cleaning the Inspection Surface
RW-05-04-002
3. Application of Penetrant
(1) After pre-treatment with cleaner, apply penetrant to
the inspection surface.
(2) Leave at room temperature for about 10 minutes.
Application of Penetrant
RW-05-04-003
5-5
4. Excess Penetrant Removal
(1) Let the waste cloth soak in the cleaner.
(2) Wipe off the excess penetrant on the inspection
surface.
DO NOT spray the solvent on the test surface directly, because
this can remove the penetrant from the flaws.
Excess Penetrant Removal RW-05-04-004
5. Agitation of Developer
(1) Shake the developer can.
(2) Shake the can several times after the agitating ball in it
sounds.
Agitation of Developer RW-05-04-005
6. Application of Developer
(1) Keep the developer about 30 cm away from the
inspection surface.
(2) Evenly spray the developer onto the inspection
surface.
Applying Developer RW-05-04-006
5-6
5-5. Ultrasonic Flaw Detection Method

Vertical Type Probe
Ultrasonic waves travel straight at a constant speed inside Probe
Inspection
a substance in the form of a sound beam (ultrasonic wave Surface
beam) having a clear boundary like the head light beam of Ultrasonic
Specimen
an automobile. However, if any obstructions such as cracks, Wave Pulse
defects, etc. exist in the passage of the ultrasonic wave, the
wave is reflected.
Ultrasonic flaw detection method utilizes these characteristics
Propagation of Ultrasonic Reflection of Ultrasonic
of ultrasonic wave technology to check whether a crack or Wave Pulse in Specimen Wave Pulse from Defect
defect exists or not. TDC-61
When using the ultrasonic flaw detection method, take the
characteristics of the defect to be checked into consideration.
 Location of defect (groove surface, root face, toe of weld T: Transmitting B:

bead, or heat affected zone) Pulse Bottom
Echo
 State of defect reflection surface (if smooth, or rough)
 Direction of defect (vertical to defect surface, parallel or F: Defect Echo
vertical to welded line)
 Form of defect (flat, spherical, or other complicated form)
Example of Flaw Detection

Display on a Picture Tube TDC-62
5-7
5-6. Magnetic Powder Method Magnetic Powders
When a ferromagnetic substance such as a mild carbon steel

or a high tensile strength steel is magnetized, magnetic
force lines are developed. If any defect exists in the magnetic
force lines, the flow of the magnetic force lines is disturbed
as illustrated in fig. (a). Then, partial magnetic force lines are
propagated through air, and magnetic poles are induced at the
both ends of the defect. Under this condition, if fine magnetic (a) Application (b) Sticking
powders are placed near the defect, magnetic powders are
successively magnetized by the magnetic field as illustrated in Principle of Magnetic Powder Method TDC-63
fig. (b) and stick to the magnetic poles. The magnetic powders
attract each other and form a pattern having a width wider
several to tens times than the actual width of the defect. Electromagnet Current
There are two methods to magnetize the base metal. One is
called a yoke method which places the check section between Specimen
the magnetic poles.
The other is called a prod method which flows electric current
directly to the base metal. Magnetic Force Line
Weld Joint
Defect
Yoke Method
Electromagnet
Current
Specimen
Magnetic Force
Line
Defect
Weld Joint
Prod Method
TDC-64
5-8
SECTION 6
RESTRAINING
– CONTENTS –
6-1. Importance of Restraining Work...................................6-1
6-2. Precautions for Restraining Work.................................6-2
6-3. Examples of Attaching Restraining Fixtures.............6-4
6-4. Precautions for Removing Restraining Fixure..........6-6
(Blank)
SECTION 6 RESTRAINING
6-1. Importance of Restraining Work

The purpose of the restraining work is to reduce distortions
arising from load, welding, and heat-treatment. When a base
metal is gouged or welded, it is heated. Then, as it cools, the
base metal shrinks, and distortion appears on the base metal.
If structural components such as a boom, arm, and bucket are
distorted, mating dimensions of them will change, scoring
the joint section and possibly making the reassembly of them
difficult or impossible, after disassembly for repair.
6-1
6-2. Precautions for Restraining Work

 Before attaching a restraining fixture to the structure,
measure the dimensions of the repair section and record
Ruler
them to check the distortion after repair welding.
TDC-47
WRONG RIGHT
 To make the most of the restraining fixture function, the

restraining fixture should be attached to the best position
to cancel out any distortions which may arise.
Restraining Fixture TDC-48
 Weld a restraining fixture to a space other than a machined WRONG

surface. If welded to a machined surface, the surface must Restraining
be machined again. Fixture
Welding
Machined Surface
TDC-50
 After checking that the tack welding was performed to the

correct dimensions as indicated on the drawing, attach
a fixture strong enough to endure against distortion.
Especially, the restraining fixture used to resist against
compressive distortion must have sufficient strength.
Use a L-shape-section steel bar at the forked section of the
boom and arm.
L-Shape-Section Steel Bar

Boom Restraint
RW-06-02-001
6-2
 Attach a restraining fixture before preheating for regular
welding. Preheating will also cause distortion when it is
cooled.
Burner
 When welding a restraining fixture to a high tensile strength

steel or to a special alloy steel, preheating is required before
welding.
Preheating RW-06-03-001
 After completing repair welding, check the dimensions and

record them.
6-3
6-3. Examples of Attaching Restraining Fixtures

 Restraining fixture attached between bosses of the boom or
arm
L-Shape-Section Steel Bar

RW-06-02-001
Boom Restraint
 Restraining fixtures limiting distortions on brackets of the

boom, arm, and center frame
Welding
Restraining Fixture Restraining Fixture 4 Pieces TDC-53
 Restraining the side plates, top plates, and bottom plates of

the boom and arm
Welding Repair Welding

Restraining Fixture
Side Plates, Top

Plates, Bottom
Plates
Pipe
Access Hole
TDC-54
6-4
 Restraining Methods for Ribs inside Boom & Arm and Yoke-
type Bracket
 Ribs inside Boom and Arm
If an arc strike impression is left on the upper section of
the rib provided inside the boom and arm, cracks may
develop from that point. Thus, welding a restraining
fixture in this section should be avoided.
TDC-55
RIGHT WRONG
Restraining Fixture
TDC-56
 If an arc strike impression is left at the plate fringe of the
yoke bracket provided at the tip end of the boom and
arm, cracks may develop from that point. Thus, welding a
restraining fixture in this section should be avoided. RIGHT WRONG
TDC-57
6-5
6-4. Precautions for Removing Restraining Fixure Small Notch Finish by Grinding
 Be sure to remove the restraining fixture after rectifying

distortion. If the restraining fixture is removed before
rectifying distortion, distortion may increase into any
direction. Rectifying the distortion may be difficult.
Large Notch Remove Remaining Beads
 After removing the restraining fixture, completely remove
the weld bead by grinding. If a large notch is left, fill the
notch by cladding and finish the bead surface flat with the
base metal.
40-50 mm (1-1/2-2”)
When the base metal is
a high tensile strength steel:
Fill Concave by Cladding Finishing by Grinding
TDC-58
6-6
SECTION 7
PREHEATING
– CONTENTS –
7-1. Preheating.............................................................................7-1
7-2. Temperature Between Welding Paths.........................7-2
7-3. Warming Up.........................................................................7-3
7-4. Postheating..........................................................................7-4
7-5. Selection of Preheating Temperature.........................7-5
7-6. Preheating Method............................................................7-6
7-7. Temperature Checking Method....................................7-7
(Blank)
SECTION 7 PREHEATING
7-1. Preheating
Weld joint and its vicinity are heated to a specified
temperature before welding. The purpose of preheating is to
allow the diffusive hydrogen in the weld metal to have enough
time to be released while cooling as the cooling speeds of
preheated base metal are slower than untreated base metal.
The additional effects of preheating are:
 Prevention of weld cracks and to ensure complete
penetration when welding base metals having self-
hardening properties.
 To help recover ductility and notch brittleness of weld
metal.
Generally, preheating for the first layer is most effective. Measuring Position of Preheating Temperature
However, it is sometimes performed to intermediate or final
RW-07-01-001
layers.
IMPORTANT: When preheating temperature is specified

on the drawing or in some instruction forms, be sure to
use the specified temperature.
When ambient temperature is lower than 10 °C (50 °F),
be sure to preheat base metal to 30-50 °C (86-122 °F ).
Preheating RW-07-01-002
7-1
7-2. Temperature Between Welding Passes

The base metals are heated while being welded. When a high
tensile strength steel is welded, the weld metal and heat
affected zone will embrittle due to welding heat. Thus, the
maximum temperature between welding passes must be
controlled in the range higher than preheating temperature
and lower than 400 °C (752 °F). (The minimum temperature is
equal to the preheating temperature.)
When welding a section close to the place where precision
parts like ball bearings are installed, the maximum
temperature between passes is sometimes restricted to
Infrared Thermometer
protect the precision part from deformation by heat. RW-07-02-001
IMPORTANT: When the temperature between weld

passes is specified on the drawing or in some
instruction forms, be sure not to exceed the specified
temperature.
Measuring Position of the Temperature between Welding Passes

RW-07-02-002
Measurement of the Temperature between welding passes

RW-07-02-003
Appropriate Temperature
Too High Temperature
RW-07-02-004 RW-07-02-005
7-2
7-3. Warming Up
The purpose of warming up are to dehydrate the surface of
the base metal and to heat the vicinity of the weld joint up to
approx. 40 °C (104 °F) before welding even if material of the
base metal is normally not preheated.
RW-07-03-001
7-3
7-4. Postheating
After welding, the weld joint is heated again. This is called
“Postheating.” The postheating is usually applied to high
carbon steels to prevent the heat affected zone from
hardening too quickly. Slow cooling after welding allows
hydrogen to be released, reduces residual stress, and prevents
the occurrence of cracks.
However, strength or toughness may be reduced by
postheating. Therefore, postheating temperature must be
correctly controlled.
RW-07-04-001
7-4
7-5. Selection of Preheating Temperature

IMPORTANT: When preheating temperature is specified
on the drawing or in instruction forms, be sure to use
the specified temperature.
The preheating temperature and the temperature between

weld passes are not selected simply by the kind of base metal.
It must be selected by the estimation formula using factors
of groove shape, chemical compositions in the base metal,
degree of restraint, and amount of diffusive hydrogen. (Refer
to “Estimate formula” in section 12 “Appendix” ) Therefore,
when performing repair welding, apply the specified
temperature indicated on the repair drawing.
Generally:
 When single-bevel groove is called for, the preheating
temperature for them is 50 °C (90 °F) higher than that for
double-V, single-V, or double-U groove.
 The higher the alloy elements such as carbon, the higher
the preheating temperature. (Degree of restraint depends
on groove shape)
 The thicker the plate, the higher the preheating
temperature.
 Manual welding requires higher preheating temperature
than semi-automatic welding.
The standard preheating temperatures are shown in the table

below:
T: Plate Thickness
Weld steel T<25 mm 25<T<38 38<T<50
JIS ASTM/AISI (T<1”) (1”<T<1-1/2”) (1-1/2”<T<2”)
SS400 36 Not required* Not required* Not required*
SM490 70 Not required* 70-120 °C
High tensile steel 50 kg/mm2 (158-248 °F)
(70 000 psi) Class 
SM570 - 50-100 °C 70-120 °C 100-150 °C
High tensile steel 60 kg/mm2 (122-212 °F) (158-248 °F) (212-302 °F)
(85 000 psi) Class 
High tensile steel 70 kg/mm2 70-120 °C 100-150 °C 120-180 °C
 (158-248 °F) (212-302 °F) (248-356 °F)
(100 000 psi) Class
High tensile steel 80 kg/mm2 100-150 °C 120-180 °C 150-200 °C
 (212-302 °F) (248-356 °F) (302-392 °F)
(115 000 psi) Class
100-150 °C
S35C 1035 (212-302 °F)
150-200 °C 200-250 °C
S45 - (302-392 °F) (392-482 °F)
200-250 °C
SCMn2B - (392-482 °F)
*: When ambient temperature is lower than 10 °C (50 °F), be sure to preheat base metal to 30-50 °C (86-122 °F ).
7-5
7-6. Preheating Method

Preheating is done by a gas torch or electric resistance heating
method. The gas torch heating method is easy to use, so this
method is widely employed for repair welding. However, Measure Temperature on This Line
heating temperature of this method must be sufficiently
controlled when heating is continued for a long time or
uniform heating at a constant temperature is required. Preheat Range 50-100 mm
When the electric resistance heating method is employed, the
temperature can be exactly controlled with a thermostat. 50-100 mm
Heat, not only the range close to the weld joint but both sides (2-4”)
of the weld joint ranging from 50 to 100 mm (2 to 4 in) (or 3 Weld Joint
times the plate thickness), to the 50-100 mm 50-100 mm
specified temperature. (2-4”) (2-4”)
TDC-69
IMPORTANT: When preheating is required, be sure to

complete welding without interruption. Maintain the
preheating temperature and the temperature between
weld passes within the specified range until the
welding is completed.
IMPORTANT: Preheating temperature for tack welding
should be approx. 50 °C (90 °F) higher than that for Supplementary Parts
normal welding, as length of tack welding is short,
increasing cooling speeds. Due to the same reason,
preheating temperature for temporarily welding of the
supplementary parts should be approx. 50 °C (90 °F) 50 °C
higher than that for normal welding. (90 °F)
Higher
If the preheating temperature is not allowed to increase for

TDC-70
some reason attributed to the weld joint construction or
work site environment, other corrective measures, such as
expanding the preheating range or using a heat insulating
material, are taken to reduce cooling speeds.
7-6
7-7. Temperature Checking Method

Excessively low preheating temperature will cause cracks at
the weld joint, and excessively high temperature will cause the
bristling of the base metal, leading to cracks of the base metal.
The preheating temperature is measured using a thermal chalk
or surface thermometer.
Measure the temperature at a location 50 to 100 mm (2 to 3.9
in) away from the joint. Generally, a thermal choke is used.
 Thermal Chalk
Utilizing change in color or state due to thermal
decomposition or fusion of compounds, temperature
is checked. This method is convenient to check if the
temperature of the preheated area is over or below the
specified temperature. However, this method cannot
measure exactly what the temperature is. Thermal chalks
are grouped and available depending on temperature
ranges to be measured. Use thermal chalk appropriate to
the application.
The following are thermal chalks recommended to have
in stock for repairing construction machineries.
Thermal Chalk RW-07-07-001
Applicable Temperature of Thermal Chalk
°C 50, 70, 100, 120, 150, 180, 200, 250
°F 120, 160, 200, 250, 300, 350, 400, 450
7-7
 Surface Thermometer
There are two types of surface thermometers, non-
contact type and contact type. The contact type is usually
comprised of a temperature sensor and a display. When
the temperature sensor is pushed against the base metal,
the temperature of the base metal is indicated on the
display.
Temperature range and sensing response vary depending
on kind of material used for the sensor. Depending
on the surface roughness of the base metal and the
contact condition of the sensor with the base metal, the
sensitivity of the contact type surface thermometer may
be affected. Take care to correctly push the contact type Contact Type Surface Thermometer
surface thermometer sensor against the base metal. Take RW-07-07-002
care to correctly push the thermometer sensor against
the base metal.
The non-contact type surface thermometer is simple and
easy to use. However, as the accuracy is relatively low
compared to the contact type surface thermometer, take
care to use it.
Non-Contact Type Surface Thermometer

RW-04-01-008
7-8
SECTION 8
GOUGING
– CONTENTS –
8-1. Gouging.................................................................................8-1
8-2. Preparation for Gouging..................................................8-3
8-3. Gouging Procedure...........................................................8-4
8-4. Finishing............................................................................. 8-12
(Blank)
SECTION 8 GOUGING
8-1. Gouging
Crack Gouging
The purpose of gouging is to completely remove defects from
the section to be welded and to prevent defects in the weld
bead of the repair welding.
If any defect should remain in the weld bead, cracks may
result.
Since gouging sparks can scatter over 10 m, be sure to
confirm safety of the surrounding workers and there are no
flammables around the area before starting work.
GO-001
1. Kinds of Gouging
Gouging methods are grouped as follows:
 Arc-air gouging
 Gas gouging
 Plasma gouging
Generally, when repairing cracks on structures for
construction machineries, arc-air gouging finished by
grinder is employed.
The arc-air gouging work method is explained in this
section.
2. Characteristics of Arc-Air Gouging

The reasons why arc-air gouging is mainly employed are as
follows:
 Comparing with gas gouging, heating is much more
concentrated, reducing distortion by heat.
 Lower potential of cracking due to thermal stress.
 High work efficiency.
 Ability to find defects as they are without compression.
8-1
SECTION 8 GOUGING
3. Kinds of Gouging Rods
Gouging rods for mild steel are as follows:
Carbon Size mm (in) Copper Applying Groove Shape mm (in) Plate
Gouging Speed
Thickness
Diameter Length Coating Current (A) mm/min (in/min) Depth Width mm (in)
5.0 (3/16) 305 (12) Coated 100-200 900-1200 (35-50) 3-4 (1/8-5/32) 7-9 (9/32-11/32) -9 (11/32)
6.5 (1/4)   200-350 900-1200 (35-50) 4-5 (5/32-3/16) 9-11 (11/32-13/32) -12 (15/32)
8.0 (5/16)   250-400 700-1000 (30-40) 5-6 (3/16-1/4) 10-12 (3/8-15/32) 12 (15/32)-
9.0 (3/8)   300-450 400-700 (15-30) 6-7 (1/4-8/32) 11-13 (13/32-1/2) 
11.0 (7/16)   400-550 300-400 (12-15) 8-9 (5/16-11/32) 13-15 (1/2-19/32) 
13.0 (1/2)   450-600 200-300 (8-12) 9-10 (11/32-3/8) 15-17 (19/32-21/32) 
4. Fundamental Precautions
 Use a dried gouging rod.
 Whenever a gouging rod comes in contact with steel, arc Carbon Electrode Air Valve Handle
will appear. Protect the environment from damage.
 Connect the torch holder to the positive terminal of the D.C.
D.C. machine. Machine
 Extend the gouging rod approx. 150 mm (6 in) from the
holder head.
 Tilt the gouging rod approx. 80 to 90°. As soon as arc
appears, blow air and move the gouging rod forward.
 Maintain air pressure within 0.6 to 0.7 MPa (85 to 100 psi).
If air pressure becomes lower than 0.4 MPa (55 psi), Torch Holder
Air
melted metal will not be easily blown off.
 In case the crack is suspected to extend while gouging is
being performed, make stopholes to prevent the crack GO-002
from propagating. (Refer to “Removal and repair of weld
defect” in section 09 “Repair Welding”)
Carbon
Air
80° to 90°
GO-003
8-2
SECTION 8 GOUGING
8-2. Preparation for Gouging

Perform the following preparation before gouging.
(1) Before gouging, check the thickness and material
of the gouging part with drawings to prevent
breakthrough.
(2) Check crack length and depth by ultrasonic flaw

detection method or liquid penetrant inspection (Dye
check) method.
(3) Before gouging, be sure to remove rust, and remove

flammable material attached on the gouged are such
as paint or oil to prevent fire.
WRONG
(4) Gouging will produce sparks. Keep inflammables

away from the gouging area.
Grease
GO-004
(5) Protect the hydraulic cylinder rod with a fire proof

cover if it is possible that gouging sparks will come in
contact with the hydraulic cylinder. Fire Proof Cover
GO-005
Hydraulic Cylinder
IMPORTANT: When ambient temperature is below 10 °C

(50 °F), warm up the base metal to 30 to 50 °C (86 to
122 °F) even if it is mild steel.
GO-012
8-3
SECTION 8 GOUGING
8-3. Gouging Procedure

1. Work Method of Arc-Air Gouging
The arc air gouging method differs depending on the
position of sight when performing the work. There are
two types of work methods, work methods (A) and (B).
Work method (A): Looking ahead of gouging
<Features>
(1) The gouging target line is easy to check. However,
small defects are difficult to find.
(2) This method is common.
The carbon length should be

about 20 cm from the torch.
Installation of Carbon Direction of Air Blow

Direction of Gouging
RW-08-03-002 RW-08-03-003
RW-08-03-001
80° to 90°
RW-08-03-005
RW-08-03-004
RW-08-03-006
8-4
SECTION 8 GOUGING
Work method (B): Looking behind the gouging
<Features>
(1) The defects are easy to find. However, the gouging
target line is difficult to check.
(2) This method is suitable for checking small defects
such as cracks.
Installation of Carbon Direction of Air Blow

RW-08-03-007 RW-08-03-009
RW-08-03-008
About 90°
RW-08-03-011
RW-08-03-010
RW-08-03-012
8-5
SECTION 8 GOUGING
2. Width of Gouging
Gouging width (W) and depth (D) should be 1:1 as much
as possible in order to prevent cracks after welding.
When it becomes deep, lower the current and take care
for cracks.
40° to 45°
Width (W)
Depth (D)
RW-08-03-013
3. Gouging under Various Situations

The gouging method according to various situations is
explained here.
1. When crack has not broken through yet:

 Gouge the crack so that 4 mm (5/32 in) or more bottom
4 mm (5/32”)
thickness is left. If 4 mm (5/32 in) bottom thickness is not or more
left, apply gouging procedure for when crack has broken
through. (If the bottom thickness is less than 4 mm (5/32
in), weld metal may pass through.)
 Make groove angle α so that torch angle and electrode
angle can meet properly.
GO-006
8-6
SECTION 8 GOUGING
2. When crack has broken through: α
 When plate thickness is 19 mm (3/4 in) or less:
 When penetration is confirmed by ultrasonic flaw
detection, gouge the crack so that 4 mm (5/32 in) or more
bottom thickness is left.
3 mm (1/8”)
 Make groove angle α so that torch angle and electrode or more
angle can meet properly. t
 After welding the front side, gouge the reverse side 3 mm
(1/8 in) or more
 As the first layer is prone to defects after welding, gouge
the back side in order to remove the first layer. 4 mm (5/32”)
or more
 Gouge the re-welded part 3 mm (1/8 in) or more. After
gouging, check for defects.
10 mm (13/32”)
or more GO-008
α0
 When plate thickness is more than 19 mm (3/4 in):

 Though the same gouging method as applied to the
plate having 19 mm (3/4 in) or less thickness is applicable,
dimension (a) shown in the figure right shall be 2/3 of
the full depth. If dimension (a) is too large, weld metal is a
increased, leading to possible distortion. t
 Make groove angle α0 and α1 so that torch angle and
electrode angle can meet properly. 3 mm (1/8”)
or more
α1
GO-009
8-7
SECTION 8 GOUGING
3. When weld joint with a backing plate is cracked: α
 Gouge only the base metal. Never gouge the backing
plate. If the backing plate is gouged and welded with
the base metal, the backing plate functions as an added
member, inducing stress concentration.
 Make groove angle α so that torch angle and electrode
angle can meet properly.
GO-010
4. When gouging is done while preventing the extension

of cracks:
(1) Stop Hole Method
Stop Hole Drill
In general, it is said that making stop holes is better
in order to prevent the extension of cracks. However,
defects by welding may occur when repairing stop
holes. Therefore, this method is applied when the repair
welding of the stop holes can be completely done.
Crack
RW-08-03-014
8-8
SECTION 8 GOUGING
(2) Tack Welding Method
1. Perform tack welding of a length of 50 mm (2 in) or
more at the center of the crack in order to prevent the
extension of cracks.
If the crack width is 2 mm (0.1 in) or more, use a patch
plate.
* 200 (7.9")
Crack opens 2 mm (0.1") or
more.
50 mm (2") or more
Patch Plate
RW-08-03-015
When using a patch plate (cross section)
* Assuming a 200 (7.9 in) mm long crack that does not
penetrate to the back RW-08-03-016
2. Gouging the range of 30 to 50 mm (1.2 to 2 in) centering

on the crack end point. Perform PT and/or MT inspection
to make sure there are no cracks in the gouged area.
The cross sectional shape of gouging parts (a) and (b) is
illustrated as section A.
* 200 (7.9")
50 (2") 50(2")
Section A
Part (a) Part (b)
Section A RW-08-03-018
RW-08-03-017
fNOTE: PT: Penetrant Testing
MT: Magnetic Particle Testing
8-9
SECTION 8 GOUGING
3. Weld part (a) and part (b). When performing multi-layer
welding, the welding start part and crater part should
not be concentrated at the same position.
* Weld until the final welding part. (Section A)
* 200 (7.9")
Section A
Part (a) Part (b)

RW-08-03-019
4. Gouge the tack welding part (part (c)) at the center.

The shape of gouging part (150 to 160 mm (5.9 to 6.3 in))
should be the shape of section B. Check that there are no
defects.
* 150 (5.9")
Section B
Part (c)
RW-08-03-022
Section B
RW-08-03-021
8-10
SECTION 8 GOUGING
5. Weld part (a).
The welding start part and crater part should not be
concentrated. (Section A)
Section A
Part (a)
RW-08-03-023
6. Perform the finish welding.

7. After welding, check that there are no cracks using PT
and/or MT inspection.
RW-08-03-025
8-11
SECTION 8 GOUGING
8-4. Finishing
After gouging, grind the gouging surface to remove carbon Gouged Surface
adhering to the gouging surface and to smoothly finish the
surface. Grinding work is required to completely remove
melted slag or carbon adhering to the gouged surface.
Otherwise, they will cause weld defects such as an incomplete Surface Finished by Grinding
fusion and weld metal hardening. Remove section shown
with by grinding.
Generally, an angle grinder (disc grinder) is used. However, a GO-011

pencil grinder is used to finish such a section as a groove root
face where an angle grinder is difficult to apply.
Pencil Grinder RW-08-04-001 Angle Grinder RW-08-04-002
8-12
SECTION 9
REPAIR WELDING
– CONTENTS –
9-1. Welding Steel.......................................................................9-1
9-2. Electrode...............................................................................9-3
9-3. Drying of Electrodes..........................................................9-6
9-4. Cleaning of Weld Section Before Welding.................9-7
9-5. Welding Current..................................................................9-8
9-6. Welding Speed....................................................................9-9
9-7. Tack Welding..................................................................... 9-10
9-8. Dimensions of Weld Joints........................................... 9-13
9-9. Precautions for Using Backing Plates....................... 9-15
9-10. Temporarily Welding of Supplementary Parts.... 9-17
9-11. Weld Distortions............................................................ 9-18
9-12. Prevention of Weld Distortion.................................. 9-19
9-13. Types of Weld Defects................................................. 9-22
9-14. Major Types of Weld Defects and
Their Causes......................................................................... 9-23
9-15. Weld Defect Check....................................................... 9-25
9-16. Visual Inspection Standard for Weld Joint........... 9-26
9-17. Removal and Repair of Weld Defect....................... 9-28
9-18. Correction of Weld Distortions................................. 9-29
9-19. Inspection After Repairing Weld Defects............. 9-30
9-20. Precautions for Semi-Automatic Welding............ 9-31
(Blank)
SECTION 9 REPAIR WELDING
9-1. Welding Steel

Major kinds of steels used for manufacturing the Hitachi
Construction Machineries are as follows:
 Rolled steels for general structure (mild steel) Repair Mild Steel
...... JIS SS400, ASTM 36 Drawing
 Rolled steels for welded structure Material:
SS400 SS400
...... JIS SM490, ASTM 70
...... JIS SM570, ASTM-
 High tensile strength steels
...... 50kgf/mm2 (70 000 psi) class
...... 60kgf/mm2 (85 000 psi) class
 Carbon steels for machine structure use
...... JIS S35C, AISI 1035
 High tensile strength carbon steel castings and low alloy Repair High
steel castings for structual purpose (Low manganese cast Drawing Tensile
Material: Steel
steels) SS400 HT60
...... JIS SCM2b, ASTM 90-60
fNOTE: JIS: Japanese Industrial Standard TDC-02
ASTM: American Society of Testing and Material

AISI: American Iron and Steel Institute
IMPORTANT: Be sure to only use materials recommended

Heat Affected Zone
by Hitachi when repairing Hitachi machines.
Weld Metal
Rolled Structure of Base Metal Coarse Grain Area
The reasons why the materials recommended by Hitachi Bond

must be used:
1. When welded under a specified condition, welding
Temperature (°C)
structural steels are of excellent weldability, retaining no Hardness (Hv)
Maximum
defect and having high mechanical properties in weld Temperature
zone. of Weld Metal
Maximum
2. Welding structural steels are preferable to those steels Hardness
that have as low of a carbon content as possible. Carbon
is one of the most influential elements to control
Hardness
characteristics of the heat-affected zone in weld zone.
The higher the carbon content in the steel, the more
liable the heat-affected zone will be to harden when Base
Weld Metal
Metal
cooled quickly, causing cracks and reducing ductility in
the weld zone.
Distance from Bond (mm) RW-09-01-001
Structure and Hardness of Weld Joint (High Tensile Strength Steel:
SM490 A)
9-1
3. Sufficient strength of a weld structure will be ensured
only when both base metals and weld zones have
adequate strength. Especially, notch sensitivity of the
material is one of the most important properties to Higher than
Preheating
prevent brittle fracture of the weld structure. Therefore, Temperature
specifications of some weld structural steels prescribe and Lower
the lower limits of Charpy impact values to be taken into than 400 °C (752 °F)
account when selecting kinds of steels.
The more heat is added, the greater the notch sensitivity
of the heat affected zone will be reduced. When high
tensile strength steels are welded with a great deal of
heat input, notch sensitivity is reduced remarkably,
requiring the limitation of heat input as necessary. (Refer
to the section 07 “Preheating”) TDC-03
Refer to the section 12 “Appendix” for mechanical

properties of each material.
9-2
9-2. Electrode
IMPORTANT: When electrodes are specified in the repair
work drawings, be sure to only use the specified ones.
1. Kinds of Electrodes
Mild Steel
A key point in determining welding quality exists in the
selection of electrodes to be applied.
 Shielded Arc Electrode for Low Carbon Steel

Types of electrodes should be selected after taking the Low Hydrogen type TDC-04
following points into account: Electrode
(1) Plate thickness

(2) Kinds of weld joints
(3) Extent of restriction against weld strains
(4) Circumference conditions at welding work site
(5) Welding efficiency
Normally, use a low hydrogen type electrode for repairing
construction machineries. Refer to the section 12 “Appendix”
for the kinds and specifications of shield arc electrodes for
mild steels.
9-3
 Shielded Arc Electrode for High Tensile Strength Steel
The shield arc electrode to weld high tensile strength steels
requires the following characteristics:
a : Weld metal possesses tensile strength and yeild point

(or proof stress) equivalent to those of base metals. In
addition, its elongation is large. High
b : Notch sensitivity of the weld metal is high. With heat Tensile
Strength
treatment applied after welding, notch sensitivity is Steel
not reduced remarkably.
c : Sensitivity against cracks shall be low. High tensile
strength is liable to induce a delayed fracture caused
by hydrogen. Therefore, hydrogen content in the Electrode for High TDC-04
Tensile Strength Steel
weld metal must be reduced sufficiently.
d : Welding work can be performed easily with few weld
defects. Consequently, excellent quality weld joints
are ensured.
Of the above items, item (3) is the most important. Normally,

welding of high tensile strength steels is performed by a
low hydrogen type electrode. The higher tensile strength
the base matal has, the less hydrogen content the electrode High
shall include to prevent the occurrence of cracks in weld Tensile
joints. Be sure to use an electrode which weld metal Strength
Steel
includes a very small quantity of hydrogen when welding
high tensile strength steels.
Refer to the section 12 “Appendix” for the kinds and Hydrogen

specifications of shield arc electrodes for high tensile TDC-05
strength steels.
9-4
2. Selection of electrodes
If improper electrodes are selected, the weld bead will not be built up correctly, resulting in weaker strength weld
joints and causing occurrence of cracks in weld joints. The following table lists kinds of electrodes matched to the
properties of steels commonly used for the construction machineries.
Selection of Electrodes Based on Kinds of Base Metals
Steel B JIS SS400 SM490 S35C HT590 HT790 SCMn2B

Steel A ASTM/AISI 36 70 1035 - - -
Welding JIS E4316
Electrode AWS E7016
SS400
Welding JIS YGW11
Wire AWS ER70S-G
Welding JIS E4316

Electrode AWS E7016
SM490
Welding JIS YGW11

Wire AWS ER70S-G
Welding JIS E4316
 
Electrode AWS E7016
S35C
Welding JIS YGW11
 
Wire AWS ER70S-G
Welding JIS E4316 E5016 E6216-N1M1 U

Electrode AWS E7016 E7016 E9016G
HT590
Welding JIS YGW11 G59JA1UC3M1T
 
Wire AWS ER70S-G ER80S-G
Welding JIS E6216-N1M1 U E7816-N4CM2 U
  
Electrode AWS E9016G E 11016G
HT790
Welding JIS G59JA1UC3M1T G78A2UCN5M3T
  
Welding JIS E4316 E6216-N1M1 U
   
Electrode AWS E7016 E9016G
SCMn2B
Welding JIS YGW11 G59JA1UC3M1T
   
fNOTE: JIS: Japanese Standard AISI: American Iron and Steel Institute
ASTM: American Society of Testing and Material AWS: American Welding Society
9-5
9-3. Drying of Electrodes

Normally, a low hydrogen type electrode is used for repairing
construction machineries. If a humid electrode is used, the
weld metal made by this type of the electrode will become
brittle, leading to ease of cracking, and allowing weld defects
like blowholes to develop. Therefore, shielded arc electrodes
and flux must be protected from humidity while in storage.
Low hydrogen type electrodes are dried at temperature of 300

to 400 °C (572-752 °F) for 30 to 60 minutes before welding. Blowhole Humidity
Depending on the brands of electrodes, drying temperatures
are specified. Thus, be sure to dry them in accordance with
their specifications. If the electrodes are not used soon after
being dried, keep them in a container maintained at 100 to
150 °C (212-302 °F) and use as needed. Take care not leave
them out of the dryer for more than two to four hours.
Never try to dry electrodes using gas burner flame.

Applying gas burner flame will humidify electrodes. TDC-06
IMPORTANT: Observe the drying conditions

recommended by electrode manufacturer.
Dryer
TDC-07
Standard drying conditions are as follows:

Humidity Range
Drying
Kinds of Steel Electrode Requiring Drying JIS AWS Drying Time (min)
Temperature °C ( °F)
(%)
70-100
ilminite Type 3 E4319 E6019 30~60
Low carbon (158-212)
steel Low Hydrogen 300-400
0.5 E 4316 E 7016 30~60
Type (572-752)
300-400
High Tensile E 5016 E 7016G 30~60
Low Hydrogen (572-752)
Strength 0.5
Type E 5816 300-400
Steel E 9016G 30~60
E 6316 (572-752)
9-6
9-4. Cleaning of Weld Section Before Welding

Adherence of rust, paint, oil, etc. to surfaces of weld sections
may cause occurence of weld defects, possibly resulting in
a serious failure of welded components. Be sure to properly
clean the weld sections before welding using a cloth, wire
brush, grinder, etc. Burning the weld sections with a gas
burner is an effective measure to remove foreign matter from
the weld sections.
IMPORTANT: While welding, sparks will fly. Always keep

inflammables away from the vicinity of the welding
work site before starting welding.
TDC-08
Oil
TDC-09
9-7
9-5. Welding Current

Improper welding current may be a cause of weld defects.
Thus, welding current must be determined with extra care.
Amount of welding current is mainly determined by the
diameter of the electrode used, taking the positioning of weld
and the type of the electrode used into consideration.
When thick plates are welded or the position of weld is Low High
downward, the current is increased. When thin plates are
welded or the position of weld is upward, the current is
reduced.
Standard amounts of welding current are shown below.
Low High
TDC-10
JIS E4316 (AWS E7016, BS E4302 B (H))

Diameter of electrode mm (in) 3.2 (1/8”) 4.0 (5/32”) 5.0 (3/16”) 6.0 (1/4”)
Downward
100-140 A 140-190 A 190-250 A 260-320 A
positioning
Current
range Vertical or
overhead 90-130 A 120-180 A 160-210 A
positioning
9-8
9-6. Welding Speed

Welding speed of a shielded arc welding electrode will be Too fast
greatly affected by the welder's skill. However, welding too fast
will reduce joint penetration and too slowly will cause poor Poor penetration
appearance of weld beads due to enfolding slags and forming
an uneven surface of weld beads.
Too slow
Enfolding slags
TDC-11
9-9
9-7. Tack Welding

Tack welding is applied to replace a part of the base metal, or
to put a cover to a access hole opened on a welded structural Strongback
component, to hold welding members in position, or to keep
Yoke
their correct groove dimentions for regular welding. Therefore,
Fillet Weld Wedge
minimum amounts and numbers of tack weld beads are
recommended. Fillet Weld
One tack-weld-bead length applied to high tensile strength
steels shall be within 40 to 50 mm (1-1/2 to 2 in) to avoid Butt Welding
excessive hardening of the base metals and occurrence of
weld cracks.
Standard tack-weld-bead length and weld bead pitch to be
applied to low carbon steel base metals are shown in the table
to the right. Wedge
Use strongbacks or falling stoppers to prevent misalignment
or distortion of the welded members during tack welding.
Use a butt setting piece to correct discrepancy of the root
edge at butt weld joints as necessary.
Use a spacer to adjust or hold the root gap to specifications. Example of Butt Setting Piece Example of Spacer
TDC-12
Plate Thickness Bead Length mm

Pitch mm (in)
mm (in) (in)
4 (5/32”) 10 (3/8”) 250 (10”)
4-28 (1/8-1”) 40 (1-1/2”) 500 (20”)
28 (1”) 70 (2-3/4”) 800 (31”)
fNOTE: Normally, the diameter of the tack weld

electrode shall be 4mm (5/32”) or less.
9-10
Precautions for Tack Welding
1. Preheat as required depending on kinds of base metals
and atmospheric temperature at the welding site.
Usually, tack-welding-bead length is short so that the
cooling speed is fast. Thus, preheat temperatures for tack
welding are recommended to be set approx. 50 °C (90 °F)
higher than those for regular welding.
RIGHT WRONG
2. Before performing tack welding, be sure to check

that the root gap dimension is set as specified and no
discrepancy at the root edge is found.
TDC-13
3. Remove rust, oil, etc. from on the groove faces or their

vicinity before performing tack welding.
TDC-14
RIGHT WRONG
4. Avoid tack welding to the weld joint corner, end face,
and from the ends as shown below. 50mm (2”)
or more
TDC-15
WRONG RIGHT WRONG RIGHT
RW-09-07-001
5. When performing tack welding to welding lines for

intermittent fillet welding, take care not to weld the Tack Welding
places where no regular weld is required. WRONG
RIGHT
Tack Welding
TDC-16
9-11
6. When specified, tack welding beads placed on important
weld joints must be removed completely, just before the
regular welding. Weld Bead
Chipping
Tack Welding
TDC-17
7. When temporarily-attached parts attached to the base

metal by tack welding are dislocated, remove the tack-
welding beads completely first. Then, repair the surface
Small Notch
with cladding, and finish the surface until the bead
Repairing by grinder
surface becomes even with the base metal. (Refer to the
group for “welding of the temporarily-attached parts”.)
Large Notch Removing by Finishing by
grinderCladdinggrinder
TDC-18
40 to 50 mm (1-1/2-2”)
(High Tensile Strength Steel)
9-12
9-8. Dimensions of Weld Joints

Shapes of weld joints shall be selected depending on kinds of
welded structures, welding purpose, and welding methods.
IMPORTANT: When the dimensions of weld joint are

indicated on the repair drawings, be sure to apply
them.
(1) Fillet Weld Joint

The dimensions of fillet weld joint are shown in the
right figure.
Throat Thickness
If leg size is not specified in drawing;
Leg size L=0.7 t1
Leg Size
RW-09-08-001
(2) Butt Weld Joint

The dimensions of butt weld joint are as follows:
Root Root RW-09-08-002
θ: Groove Angle c: Groove Depth

φ: Bevel Angle r: Groove Radius
a: Root Gap
b: Root Face
Unit: mm
Type of Sketch Plate
1.5 2.3 3.2 4.5 6 8 9 10 12 14 16 19 22 25 28 32 36 40 45 50 55 65 70 80 90 100 112 125 Chipping
Groove Drawing Thickness
Single-V
Groove Required
Double-V b
7 8 9 11 12 13 15 17 18 22 23 27 30 33 37 42
Groove
Required
a
11 12 13 15 16 17 19 21 22 26 27 31 34 37 41 46
Double-U b
18 22 23 27 30 33 37 42
Groove
Required
c
22 26 27 31 34 37 41 46
Single-
Bevel Required
Groove
9-13
Double-V groove type weld joints are often employed in
welding repair work of construction machines to avoid
incomplete fusion and/or growth of notches leading to stress
concentration.
If backing weld is difficult like a box section structure, only
front side welding is applied by the single-V groove weld joint
with backing plates.
If the root gap of the butt weld joint should be prepared
beyond specification, causes of weld flaw, large weld
deformation, and residual stress may result. Accodingly, if the
root gap is 5 mm (3/16 in) or more, attach backing plates, and
modify the groove size by overlaying to specifications. Then,
after performing the regular welding, remove the backing V-shaped Groove by using Backing Plate
plates. RW-09-08-007
If the root gap should be too wide to modify, replaced the
base metal with a correct one.
Overlaying Finish the surface
(Cladding by welding) with a grinder
5-16 mm
(3/16-5/8”)
Base Base
metal metal
16 mm (5/8”)<G<25 mm (1”)
Remove all backing Remove all backing
plates after welding plates after welding
and finish the surface
with a grinder. TDC-23
9-14
9-9. Precautions for Using Backing Plates

When repairing the inside of a box-section-type structure,
usually a access hole is prepared on the surface of the
structure and the repair work is done through the access
hole. Then, after completing the repair work, the access hole
is required to be covered by welding a plate using backing
plates. Accordingly, tack welding of backing plates is essential
in this case. However, improper tack welding of backing
plates will cause the occurrence of cracks in the weld joints.
Therefore, be sure to follow the precautions below:
1. Material used for the backing plate
The properties of the weld metal will be affected by the

material of the backing plate so that the material of the
backing plate must suit the property of the base metal. If a
copper backing plate is used, copper will be melted by weld Backing plate
arc, mixing with weld metal and causing the occurrence of
cracks of the weld joint.
RW-09-09-001
2. Installing the backing plate

[Vise-Installed Example]
Base metal Vise
Install the backing plate with no gap between the back
metal and base metal. If any gap is provided between
them, the weld metal will melt in the gap, forming a notch Less than
0.5 mm
inducing stress concentration. Use a backing plate holding
device like a vice to eliminate gaps as necessary. Gap
between the backing plate and metal must be less than 0.5
mm (20/1 000 in).
Backing plate
TDC-24
3. Tack welding of the backing plate
When installing the backing plate for covering the access Completely
RIGHT WRONG
remove
hole by tack welding, weld the backing plate at the weld Base metal
the tack
Outside
groove, as illustrated in the figure to the right. Then, remove welding
the tack welding beads one by one just before a regular beads using
a grinder
weld is performed on it. just before
When using a flat-bar-type-backing plate, avoid performing the regular
tack welding in the range approx. 40 to 50 mm (1-1/2 to 2 welding.
Backing plate
in) from the end-edge corner of the backing plate.
TDC-25
RIGHT WRONG
End
Maintain Backing plate
40 to 50 mm distance
(1-1/2 to 2”) TDC-26
9-15
4. Root gap RIGHT WRONG
When performing welding with backing plates, be sure to

use a correct root gap.
Backing
 If the root gap is too small,: Plate
incomplete fusion may result, leading to the bead cracking. Root gap is
too large.
Root gap
 If the root gap is too large,: is 4 to 6 mm Deep penetration
(5/32 to 1/4”). is obtained WRONG
a large extent of the backing plate is melted by welding.
Then, the backing plate and base metals are combined
together as if they have become into one piece of metal
having a sudden increase in thickness at the weld joint.
This sudden increase in thickness may be a cause of stress
concentration. Root gap is
too small.
IMPORTANT: When materials and dimensions of backing Lack of fusion
TDC-27
plates are specified in the repair drawing, be sure to
use these specified materials and dimensions.
9-16
9-10. Temporarily Welding of Supplementary

Parts Supplementary Parts
During tack welding, the welding members should be

held in correct positions or must be restricted to prevent
misalignment due to thermal distortion. For these purposes,
many types of supplementary parts (kinds of holding jigs) are
temporarily welded to the base metals. Accordingly, they are
welded strong enough to allow them to function as holding Min.
jigs, but their welding must be performed with care not to 40 to 50 mm
have an inverse effect on the base metal strength. (1-1/2 to 2 in)
TDC-28
If thick plates or high tensile strength steels are welded, weld
flaws such as excessive hardened areas or weld cracks are
liable to appear in the base metals. Even when supplementary
parts are temporarily welded to thick plates or to high tensile
strength steels, preheat the base metals sufficiently, and
perform welding with the appropriate electrode with extra
care. In addition, similarly in tack welding, the minimum
length of weld should be 40 to 50 mm (1-1/2 to 2 in).
Small Notch
If undercuts or spots of arc strikes remain, they will form Removal by Grinding
notches on the surface, causing cracks. Therefore, remove
them sufficiently using a grinder. The spot of arc strike is locally Large Notch Removing by Finishing by
hardened, potentially causing cracks at the bended corner of grinderCladdinggrinder
the plate even if finished by a grinder. Consequently, be sure
to avoid welding temporarily welded parts to the bent corner TDC-18
40 to 50 mm (1-1/2 to 2”)
of plates. High Tensile Strength steel
9-17
9-11. Weld Distortions

Steels are rapidly heated and cooled when they are welded.
Expansion in area A
Therefore, distortions of steel plates by weld heat are is absorbed in area B.
unavoidable. However, distortion will increase stress and
cracking potential in welded members. Thus, distortion must
be held to a minimum.
(a) Heating (b) Expansion

The shrinkage in the expanded area A
does not balance with the expansion in
area B, causing the entirety to deform.
(c) Cooling/Shrinkage (d) Deformation

RW-09-11-001
Weld Deformation Welding Direction
(B) Longitudinal (C) Rotary

(A) Lateral Shrinkage Deformation
Shrinkage
Butt Weld Joint
(E) Longitudinal bending

deformation
Fillet Weld Joint (F) Buckling deformation

(D) Examples Lateral Deformations
RW-09-11-002
9-18
9-12. Prevention of Weld Distortion

1. General precautions.
The following measures are generally used to prevent weld
distortions.
 When repairing an open section structural member like an

end bracket of the cylinder, boom, and arm by welding, use
some restraint fixtures, as illustrated.
L-shape-section steel bar Boom Restraint RW-06-02-001
Ruler
 Before welding the restraint fixtures, make certain of the
original dimensions between the brackets.
 Take care not to increase preheating temperature too much

and avoid overheating beyond the range required.
TDC-30
 In principle, weld in the backstep method. The backstep

method is suitable when the area to be repaired is large or
the jack is difficult to use. Burner
TDC-31
Bead Build-up Sequence
 Avoid welding in an upward direction if possible. When

welding on front attachment, move the front attachment
to such position as welding is performed in a downward
direction. Weld Progress Direction
 Avoid preparing grooves that are too large. Prepare grooves TDC-32
Horizontal Downward
uniformly.
TDC-33
 Avoid extending weld bead leg length unnecessarily.
TDC-34
9-19
2. Preventive measures against distortions
There are many kinds of welding methods and procedures
to reduce weld distortions.
 Symmetrical method
Start welding from the center of the weld line and weld
outwards within a certain length of the range in the Bead Build-up Sequence
numerical order, as shown in figure (a).
 Backstep method Welding

Weld Progress Direction Direction
Start welding from the right, and progress to the left
by welding within a certain length of the range in the (a) Symmetrical Method Sequence (d) Predistortion Method
numerical order, as shown in figure (b). Bead Build-up Sequence
 Skip method
Weld within a certain length of the range skipping one or
Weld Progress Direction
two ranges in the numerical order, as shown in figure (c).
(b) Backstep Method Sequence (e) Restraining
 Predistortion method Bead Build-up Sequence
Anticipate distortions caused by welding beforehand. Then,
provide predistortions before welding, as shown in figure
(d).
Weld Progress Direction
 Restraining (c) Skip Method Sequence

Prevent occurrence of distortion by fixing weld members. RW-09-12-001
 Peening
Tap welded beads with a peening hammer. Residual
stresses and distortion are reduced by plastically working
weld metals.
Peening method is widely employed since it is easy to apply
and have great practical results.
9-20
3. Prevention of warp on weld metal surface RIGHT
Rear Front Front Rear
 To prevent the base metal from warping, when welding
both front and rear sides of the base metal, be sure to weld
both sides in the same direction, as illustrated.
WRONG
Rear Front Front Rear
TDC-35
 When multi-layer welding on both side, build weld beads

equally.
RIGHT
WRONG
RW-09-12-002
9-21
9-13. Types of Weld Defects

1. Examples of weld defects
(11) Slender slag included
(1) Incomplete fusion (6) Blowhole between weld layers.
(2) Incomplete fusion (7) Blowhole (12) Slender slag included between
base metal and weld metal.
Pit
(3) Crack (8) Blowhole
(13) Slag included in weld metal
(9) Incomplete fusion between

(4) Crack weld layers.
(14) Hollow pit
(10) Incomplete fusion between

(5) Crack base metal and weld metal.
(15) Burn through
(17) Dangling
(16) Dripping
(18) Undercut
(19) Overlap
2. Incorrect bead forms
Throat
a) Too large actual throat b) Too small actual throat c) Overlap
d) Undercut e) Incomplete amendment of crater TDC-36
9-22
9-14. Major Types of Weld Defects and Their

Causes
1. Internal defects
Types of defect Forms of defects Causes of defects

Blowhole 1. Insufficient drying of electrode.
2. Insufficient supply of carbonic acid gas.
3. Improper flow amount of carbonic acid gas.
RW-09-14-001
4. Incomplete gas shield.
5. Inferior carbonic acid gas purity.
6. Spatters adhered to the nozzle block carbonic acid gas flow.
7. Rust, paint, grease, oil, or dust is sticking on weld metal.
8. Oil is sticking on core wire.
9. Excessive arc length.
10. Core wire is excessively extended from the nozzle end.
11. Poor conductivity of the grounding cable.
RW-09-14-002
12. Incomplete gas shield caused by weld joint form. Use an

intercept plate of gas shield flow.
Intercept
Plate RW-09-14-003
Cracks 1. High contents of carbon and other alloying element in the base
metal.
Bead Cracks Traverse Longitudinal
Crack Crack
RW-09-14-004
2. Restraint is too tight.
Crack in Heat-Affected Zone
Under
bead Crack
3. Small groove angle.
Toe
Crack
RW-09-14-005
Crater Crack
Star-shaped Crack 4. Incomplete amendment of crater.
Longitudinal Crack
Traverse Crack
RW-09-14-006
Slag Inclusion 1. Incomplete removal of slag.
2. Slow welding speed.

RW-09-14-007
3. Small welding current.
9-23

Poor Penetration 1. Small welding current.
2. High are voltage.
3. Precedence of melting metal due to slow welding speed.
RW-09-14-008
4. Weaving in the first layer.
5. Eccentric core wire center.
6. Oscillation of core wire.
7. Disturbance by tack weld bead.
RW-09-14-009 8. Small groove angle.
2. External Defects

Undercut 1. High arc voltage.
2. Large welding current.
3. Fast welding speed.
4. Eccentric torch center. (Horizontal fillet weld)
RW-09-14-010
Overlap 1. Large welding current or low arc voltage.

2. Slow welding speed.
3. Eccentric torch center. (Horizontal fillet weld)
RW-09-14-011
Meandering of 1. Malfunction of wire straightening device.
bead
2. Wire extended too long.
3. Worn tip.
RW-09-14-012
9-24
9-15. Weld Defect Check

Weld defect shall be checked by a non-destructive inspection.
Refer to the section 05 “Inspection of cracks” for the inspection
methods.
9-25
9-16. Visual Inspection Standard for Weld Joint

Major visual inspection standards for weld joint are as follows:
 Undercut
Undercut should not be noticeable.
Undercut
 Blowholes on Bead Surface
Allowable limit numbers: Four (4) per bead length of 500
mm (20 in). However, the diameter of a blowhole should not TDC-37
exceed 2 mm (80/1 000 in). If one blowhole has the larger
diameter than 2 mm (80/1 000 in), this weld should be
rejected.
Extent of concentration: 2
Extent of concentration means the total numbers of the
blowholes in the area of 10 mm × 50 mm (3/8”×2”) where
intensive blowholes exist. Overlap
 Overlap
No overlap should be found. TDC-38
 Weld Crack
Any kinds of weld cracks should be rejected.
 Joint of Weld Bead

Joints of weld beads should be smoothly connected to a
bead with as little overlay as possible.
Allowable thickness of the bead overlay: below 2 mm (80/1
000 in)
Joint of Weld
Bead
 Crater
Crater section should be refilled as flatly as possible. Thickness of
Bead Overlay
Allowable depth of the hollowness: less than 1 mm (40/1
000 in)
TDC-39
9-26
 Deviation in bead width (A1-A2):
4 mm (5/32 in) or less per 50 mm (2 in) bead length
A1
A2
L
50 mm (2 in)
TDC-40
 Height of reinforcement (when no flat finishing is required):

Manual welding:
Downward : 3 mm (1/8 in) or less
Vertical : 4 mm (5/32 in) or less
Upward : 5 mm (3/16 in) or less
Semi-automatic welding:
Downward : 4 mm (5/32 in) or less
Finish by
grinder
TDC-41
9-27
9-17. Removal and Repair of Weld Defect

First, confirm the exact location of the weld defect to be
removed by non-destructive inspection.
Remove the weld defect using a grinder or arc-air gouging.
Then, check that the weld defect is completely removed by a
liquid penetrant inspection or similar inspection procedure.
Slag inclusion, Remove weld defect

blowhole, etc. by arc-air gouging Rewelding
Reinspection
(a) Using a smaller diameter

of the electrode, reweld Remove overlap.
Slight undercut the undercut section. Overlap Reweld as necessary
(b) (c)
Examples of Repairing Weld Defects RW-09-17-001
Repair weld cracks in the following procedures:

(1) Check the crack length.
(2) If the crack is supected to extend while the crack is
being removed, make stopholes slightly outside both
ends of the crack.
(3) Make a groove so that repair welding is properly
performed.
(4) After welding, finish the weld bead surface to make
the connection with the existing weld line smooth.
Traverse crack Drills stop holes Gouge crack and make grooves
Longitudinal crack Drills stop holes Inspect again
RW-09-17-002
9-28
9-18. Correction of Weld Distortions

Weld repairing work will cause the welded structure to distort.
Therefore, check and correct the weld distortions after welding
referring to the following tips:
 During the welding work, check and record which direction
or how many distortions (bendings) are arising.
 If restraining fixtures have been welded before welding,
correct the distortion without taking off the fixtures.
 If fixtures have been not welded, support the welded
structure firmly and correct the distortions using a hydraulic
L-shape-section steel bar Boom Restraint RW-06-02-001
jack, journal jack, or chain block.
 Correct the distortions by heating and quenching the
opposite sides of the distorted sections.
 Heat with a gas burner. Sufficiently take care to heat the
correct positions, and ranges in proper sequence.
 Heating depth in plate thickness direction should generally Jack
be approximately 1/2 of the thickness, though it may vary
depending on the actual thickness of the plate. Repair
 When necessary to quench, spray water by air pressure. Welding
If both right and left sides or more than two places are
required to be quenched, cool all of them simultaneously.
 Avoid heating and quenching the same place more than
TDC-42
twice.
 Unless specifically indicated, materials such as high tensile
strength steels should avoid heating and quenching.
 When a high tensile strength steel is used, never heat and
quench the weld bead only. Burner
1/2 t TDC-43
9-29
9-19. Inspection After Repairing Weld Defects

1. Importance of Inspection
After removing weld defects and performing weld repair
works, be sure to check whether the defects previously
recognized are repaired completely. Even if crack could be
removed by appropriate measures, new cracks are liable
to develop and extend sequentially after repair welding is
made.
Therefore, inspection after welding is required. However,
when high tensile strength steels or carbon steels for
machine structural use are used, they may easily develop
delayed fracture after being rewelded so that inspection
should be performed after 8 to 24 hours.
2. Inspection
Refer to the section 05 under the title of “Inspection of
Cracks” for the inspection methods of the weld defects after Examples of Photos
weld repair work.
It is recommended to take a photo of the weld repair work
after it is completed to put it on record. When taking a
photo of the rewelded section, be sure to take a photo
of a ruler placed close to the rewelded section together Ruler
to enable the dimensions of the rewelded section to be
checked later. TDC-44
If report of crack reparing is required for warranty claim
application and other reasons, use “Repair Welding Report
Form” in the section 12 “Appendix”.
9-30
9-20. Precautions for Semi-Automatic Welding

Gas shield of semi-automatic welding is liable to inversely be
affected by wind speed even if wind speed is 1.5 to 2 m/s (5 to
6.5 ft/s). When repairing a construction machine outdoor, be
sure to screen the machine from the wind using curtains and a
rigid-box-type frame.
Curtains RW-09-20-001
Curtains RW-09-20-002
9-31
MEMO
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
9-32
SECTION 10
REINFORCEMENT
– CONTENTS –
10-1. Precaution for Reinforcement.................................. 10-1
10-2. Preparation for Reinforcement................................ 10-2
10-3. Precautions for Installation of
Reinforcing Plate................................................................ 10-4
10-4. Examples of Reinforcement...................................... 10-6
(Blank)
SECTION 10 REINFORCEMENT
10-1. Precaution for Reinforcement

When reinforcement is required after repairing cracks, perform
reinforcement in accordance with instructions in the drawing
approved by Hitachi for the location and size of the reinforing
plate, welding method, and finishing.
If a reinforcing plate is carelessly added, it may inversely
increase stress concentration, leading to the occurrence of
new cracks. Therefore, proper procedures must always be RF-001
followed.
IMPORTANT: Be sure to follow the instructions given in

the repair drawing for reinforcement.
10-1
10-2. Preparation for Reinforcement

The followings are general precautions required for preparing
the reinforcement.
 Remove spatters and slag by gas cutting.
RF-002
 Finish the gas cutting surface smoothly by grinding, and

remove sharp edges.
RF-003
10-2
 Remove rust, paint and oil from the weld groove surface.
TDC-14
Reinforcing Plate WRONG
 Eliminate gap between the base metal and the

reinforcing plate. Remove any distortion from the
reinforcing plate by appropriate methods beforehand.
Base Metal RF-004
10-3
10-3. Precautions for Installation of Reinforcing Tack Welding

Plate
1. Elimination of gap between plate surfaces
Weld First
When welding a plate onto another plate, allowable gap
limit between plates shall be 0.5 mm (20/1000 in) or less. If
the gap is too large, the reinforcing plate does not function
properly. Rectify the gap using restraint fixtures.
Press with a bolt. RF-005
Wedge
Press with a wedge. RF-006
Crowbar
Weld while pressing with a crowbar. RF-007
RIGHT
2. Partitioning of Reinforcing Plate

Depending on the size of a access hole provided on a box-
section structure, the maximum size of the reinforcing plate
to be brought into the inside of the box-section structure
is limited. Therefore, if a large area of reinforcement is or
required, reinforcing plate is sectioned so that it can be
brought into the structure. However, if the sectioning of the
reinforcing plate is carelessly made, the potential of high
stress is increased, leading to premature cracks at the weld
Welding at low stress section. RF-008
joint.
IMPORTANT: When the reinforcing plate must be WRONG

sectioned, be sure to partition the reinforcing plate
in accordance with instructions given in the Hitachi Welding at high stress section.
repair drawing.
RF-009
Reinforcing Plates
fNOTE: Stress concentrated areas in the above

illustrations are for illustrative purposes only.
10-4
3. Plug Welding not Recommended RIGHT
Plug welding is often used to attach an abrasive-resistant
material onto the bucket. Moreover, this plug welding is not
effective for reinforcement and increases the chances of
causing new cracks. Anti-Wear
Plate
IMPORTANT: Unless otherwise specified in the repair

drawing, avoid plug welding to attach reinforcing
plates.
RW-03-03-002
WRONG
Reinforcing Plate
RW-03-03-003
4. Repairing Cracks on Reinforcing Plate WRONG

When cracks develop on the reinforcing plate, remove and
replace the cracked reinforcing plate. Then, after repairing
cracks on the base metal, reweld a new reinforcing plate.
IMPORTANT: If the cracked reinforcing plate is gouged,

rewelded and used again as it is, the rewelded section
behaves like a plug welded one, increasing the
potential of causing cracks repeatedly.
RF-012
WRONG
5. Adding Ribs for Reinforcement not Recommended
Adding ribs inevitably induces stress concentration in other
sections. Accordingly, do NOT add ribs unless instructed in
the repair drawing.
RF-013
10-5
10-4. Examples of Reinforcement

The followings are examples of reinforcements widely used.
IMPORTANT: Be sure to follow instructions given in the

repair drawing for reinforcement.
 Reinforcement of Weld Bead
Crack Gouging
RF-014
 Reinforcement of Base Metal - (1)

Base Metal Reinforcing
Plate
Crack
Gouging RF-015
 Reinforcement of Base Metal - (2)
Reinforcing
Crack Plate
Crack
RF-016
 Reinforcement at a Sloping Section Reinforcing

Limit the range covered with a reinforcing plate on a flat Plate Extend Bead
area, and extend weld bead by cladding as illustrated to the
right. Finish the bead surface by grinding.
RF-017
10-6
 Welding Two Reinforcing Plates of Different Thickness
Stress will be concentrated in the place where thickness
changes. Therefore, the joint section must be finished so
that the thickness changes smoothly.
t1
×(3 to 5)=L
t Finishing by Grinding
RF-018
 Grinding Weld Bead Ends of Reinforcing Plate

Extend fillet weld beads from the reinforcing plate edges
and finish the bead ends smoothly by grinding. Extend weld bead
approx. 30 mm (1-1/8”)
Reinforcing and finish the bead
Plate ends smoothly
Side Plate or Top and Bottom Plate

RW-10-04-001
 How to Connect Weld Bead of Reinforcing Plate with Weld

Bead of Base Metal
If the weld bead of the reinforcing plate is connected with
the weld bead of the base metal at an acute angle, stress is Connect the Bead smoothly
concentrated, causing the occurrence of cracks. Extend the Reinforcing
weld bead of the reinforcing plate to connect with the weld Plate
bead of the base metal smoothly. If a hollow area is formed
between the beads, fill up the hollow section with weld
bead and finish the bead surface smoothly by grinding.
Side Plate or Top and Bottom Plate
Build up weld bead smoothly.

RW-10-04-002
10-7
MEMO
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
..................................................................................................................................................................................................
10-8
SECTION 11
FINISHING
– CONTENTS –
11-1. Importance of Finishing............................................. 11-1
11-2. Kinds of Grinders........................................................... 11-2
11-3. Proper Use of Grinder.................................................. 11-5
11-4. Direction of Grinding................................................... 11-6
11-5. Finishing Joint of New Bead with Old Bead........ 11-7
11-6. Use of R-Gauge.............................................................. 11-8
(Blank)
SECTION 11 FINISHING
11-1. Importance of Finishing (Both-side-fillet Weld Joint:

Under repeated tension load)
High stress concentration at a weld-bead-toe end can be Finishing by
reduced by finishing the surface with a grinder. According to Grinding
test results, when the bead toe end is finished by grinding, the
life time of the weld joint is extended approx. five to ten times
As Welded
longer than that of the weld joint left as welded. Range of
Refer to “Fatigue Strength and Importance of Grinding Finish” Nominal
in the section 12 ”Appendix” of this manual. Stress
IMPORTANT: Be sure to finish by grinding when indicated

in the drawing.
Cycle Time (Life Time)
Fatigue Strength Diagram FN-001
11-1
11-2. Kinds of Grinders

Grinders are grouped by kinds of power applied and their
shapes. Select the most proper grinder depending on
applications. Selecting the improper grinder to the application
will decrease finishing work efficiency, cause faulty finishing,
and reduce fatigue strength.
FN-002
11-2
1. Air Grinder
Comparing with an electric grinder, an air grinder is lighter
in weight, reducing the physical burden to a worker when a
grinding work is performed for a long time.
 Pencil Grinder
A small and light grinder. This grinder is used to slightly
finish the fringe of the base metal, inner or end surface of
a small diameter bore, and weld bead surfaces located at
a corner.
Pencil Grinder
RW-11-02-001
Tungsten Carbide Cutter

The tungsten carbide cutter is attachable to a pencil grinder,
and has a greater ability for cutting and grinding comparing
to a grinder. Thus, this cutter is suitable to a work requiring a
great amount of cutting and/or grinding.

RW-11-02-002
 Straight Grinder
Suitable for finishing a wide-range of curved surfaces
or a corner surface of cladding. Two types of grinding
stones are available. One is used to medium speed such
as a max. 2000 m/min circumferential speed, and the
other is used to high speed such as a max. 3000 m/min
high circumferential speed. Select the grinding stones to
match the application speed.
Straight Grinder
RW-11-02-003
11-3
 Angle Grinder
An offset-type grinding stone is installed. With the
circumference and one side surfaces of the grinding
stone, a flat surface is ground. This grinder can be used at
high speed, and has a greater grinding ability.
The following works are mainly performed with this

grinder:
 Finishing a raw material surface by grinding.
 Removing burrs of base metals.
 Finishing gas-cut or gouged groove surfaces.
 Finishing impressions of tack welding.
With a disc sand paper or wire brush wheel installed, this
type of grinder can be applied to works such as removing
rust on structures or polishing structure surfaces.
Angle Grinder
RW-11-02-004
2. Electric Grinder (High-Frequency Grinder)

The rotary speed of the electric grinder is not influenced
by variation of grinding load, offering a great grinding
power which is an advantage in performance of the
electric grinder. Generally, a three-phase induction motor is
employed.
11-4
11-3. Proper Use of Grinder

Depending on kinds of applications, use the most proper type
of grinder. The following are examples showing how to select a
proper grinder:
1. Rectifying Weld Groove after Gouging

Generally, an angle grinder is used. When finishing is
difficult in such a places as a root of weld, a cemented
carbide cutter is used.
Remove the hatched area smoothly

FN-003
2. Finishing bead surfaces after the repair welding is

completed
 When the welding line is straight:

Kind of Grinder : Angle Grinder + Straight grinder
Grain Size of Grinding Stone :
#24 or 36 for rough cutting
#60 or 80 for finishing
Grinding Direction : Arrow direction shown in the
figure to the right.
FN-004
 Corner Section:
Kind of Grinder : Pencil Grinder
Grain Size of Grinding Stone:
#24 or 36 for rough cutting
#60 or 80 for finishing
Grinding Direction : Arrow direction shown in the
figure to the right.
FN-005
11-5
11-4. Direction of Grinding

Since notches and scratches that occur in the direction of
grinder disk rotation will cause cracks to recur, finish them
securely so that they do NOT exist.
Grinding Notch
Crack Grinder
SA-006A
11-6
11-5. Finishing Joint of New Bead with Old Bead

The joint form of repair weld bead with old bead will easily
vary depending on welding positions and conditions. If
the joint area has a remarkable change like a step, stress is
concentrated in that area, resulting in breaking. Accordingly,
when finishing the weld bead joint by grinding, it is
important to finish the bead joint area smoothly. Especially,
if an undercut is existing at the bead joint, be sure to fill the
undercut area with a weld bead. Then, finish the surface of the
bead smoothly by grinding.
11-7
11-6. Use of R-Gauge

Manufacture a standard R-gauge to simply monitor a
surface form. When finishing R-corners using an R-gauge,
R gauge
uniform corner surface can be easily obtained. Be sure to
use an R-gauge when finishing the R-corner surface of the
reinforcement by cladding.
FN-008
11-8
SECTION 12
APPENDIX
– CONTENTS –
12-1. Nominal Stress and Stress Concentration............ 12-1
12-2. Crack at Weld Joint....................................................... 12-2
12-3. Fatigue Strength and Importance of
Grinding Finish.................................................................... 12-3
12-4. Mechanical Properties of Welding Steel............... 12-4
12-5. Specifications of Shield Arc Electrodes for
Mild Steel............................................................................... 12-5
12-6. Specifications of Shield Arc Electrodes for
High Tensile Strength Steel............................................. 12-6
12-7. Estimation Formula of Preheat Temperature...... 12-7
12-8. Crack Report................................................................... 12-8
12-9. Weld Terms....................................................................12-14
(Blank)
SECTION 12 APPENDIX
12-1. Nominal Stress and Stress Concentration

When a load is applied to a structural member, inner force External Force
arises in the member to balance with the load. Inner force
per unit section area of the member is called “stress.” In a
uniform section, stress is uniformly distributed throughout the
section and directed toward the load direction. On an actual
machine, however, the section area of the structural member
is generally not uniform. When the section area changes
smoothly, change in stress is negligible. But, when the section
Inner Force
area changes sharply, stress distribution changes greatly at the
section area change corner.
AP-001
An example of stress distribution on a box-section-type Additional Plate

structure is illustrated to the right. When an additional plate Weld Bead
or block is welded on the surface, the section area at that Load
section changes so that stress distribution on that section
also changes, increasing stress at the section on which the
plate or block is welded. Stress change due to change in the
Added Local Stress
section area or form is called stress concentration, the ratio of Member
which is defined as “stress concentration factor.” Stress on the
uniform section area is called “Nominal Stress” which is used
as a standard stress when the stress concentration factor is
calculated.
AP-002
Stress concentration factor = Local stress / Nominal stress

R
Correlation between the stress concentration factor and θ

change in area or form have already been studied and
acquired in various typical changes of forms. One example t
of them is shown to the right. This is an example of stress h
concentration factor for a member to which a tension load is
applied.
θ=90 °
The stress concentration factors vary depending on corner
angle θ and curvature radius R. The larger corner angle θ or the
smaller curvature radius R, the higher stress will develop at the Stress θ=45 °
Concentration
change corner of the section area. Factor
θ=15 °
To prevent an excessively high local stress from arising, the

section area form or thickness of the member should change
smoothly. R/h
Example of Stress Concentration Factor
AP-003
12-1
SECTION 12 APPENDIX
12-2. Crack at Weld Joint

Structures are repeatedly exerted by dynamic variable loads.
Therefore, the material strength of the structure at a stress
concentrated section such as a weld joint will be gradually
reduced by high stress developed repeatedly, causing a subtle
crack to arise. Once a crack has developed, stress at the tip
of the crack will greatly increase. Thus, the crack is gradually
extended by loads applied repeatedly afterward, ultimately
leading to fracture of the structure.
Construction of Weld Joints
Major types of weld joints used in the front structure of the
hydraulic excavators and the section forms of their weld beads
are shown in the right figures.
Normal Bead Molded Bead Finishing Multi-layer

by Grinder Built-up
AP-004
The types of cracks which develop around weld joints are

grouped into three categories as shown below.
 Cracks starting from the toe of fillet weld bead (1 or 2).

 Crack starting from the incomplete fusion area of one-
side-weld joint (3). Undercut Overlap
 Crack starting from the gap between the base metals and
backing plate (4).
Bulkhead
Whether a crack develops or not from the toe of fillet weld (1) (3)
bead greatly depends on the smoothness of the bead form. A
Thus, the toe of weld bead should be smoothly finished by a
grinder after removing undercut or overlap of bead, if any, as
they will cause the reduction of material strength. When weld A
joint with backing plate or one-side-weld joint is employed, a
crack is liable to start from the gap between the base metals
and backing plate or the incomplete fusion area of one- (2)
side-weld joint, as they constitute weld defects. The stress Gap
concentration factor at the toe of fillet weld bead is approx. 3 (4)
when the bead is left as welded. After finishing the toe of the Backing Plate
bead smoothly by molding or grinding the bead, the stress
Types of Cracks Developed at Weld Joints AP-005
concentration factor can be reduced to 1.6 to 1.8.
12-2
SECTION 12 APPENDIX
12-3. Fatigue Strength and Importance of

Grinding Finish
(Both-side-fillet weld joint: Under repeated tension load)
The fatigue strength of a weld joint is improved by finishing
the toe of the weld bead smoothly. The figure on the right is 5 to 10 Times
an example of a fatigue strength diagram for both-side-fillet
weld, in which two lines are shown for comparison. One is Finishing
the fatigue strength line for the weld joint left as welded. The by Grinding
Range of
other line is that for the weld joint finished by grinding. When Nominal
finished by grinding, the local stress at the toe of weld bead is Stress As Welded
reduced, so that life time of the weld joint is extended approx.
five to ten times longer than that of the weld joint left as
welded.
105 106
Accordingly, to prevent cracks from occurring again after
Cycle Time (Life Time)
repairing initial cracks on structures, it is essential to reduce
the stress concentration at the toe of weld bead as much as Fatigue Strength Diagram AP-006
possible, and eliminate inner defects that may induce hair
cracks in the weld joints. High stress at the toe of the weld
bead can be reduced by finishing the toe surface of the weld Horizontal Downward Finishing by Finishing by
bead after repairing. However, if any weld defect such as an Weld Weld Molding Grinding
incomplete penetration is remaining inside the weld joint, 0.1~0.2 0.2~0.3 0.6~0.7 1.0
sufficient repairing results will not be obtained.
Reduction Factors of Fatigue Strength
by Welding Methods
12-3
12-4. Mechanical Properties of Welding Steel
MECHANICAL PROPERTIES OF WELDING STEEL
Kind of Steel Chemical compositions % Yield points or Proof stress Tensile Impact
kgf/mm2 (N/mm2) strength value
Plate thickness mm kgf/mm2 kg-m/cm2
(N/mm2) (J/cm2)
C Si Mn P S Ni Cr Mo T 16 16<T 40 T>40
SS400 (JIS) 0.050 0.050 17 (167) 41-52

36 (ASTM) 0.25 0.04 0.05 25.3 (248) 40.8-56.2
SM490 (JIS) 0.18 0.55 1.50 0.040 0.040 33 (324) 32 (314) 30 (294) 50-62 2.8 (27)
70 (ASTM) 0.27 0.15-0.40 0.85-1.20 0.040 0.050 29.5 (289) 49.2-63.3 @ 0 °C
12-4
High tensile
60-72 4.8 (47)
steel 60 kgf/mm2 0.13 0.15-0.55 0.90-1.50 0.03 0.03 0.60 0.03 0.03 46 (451) (588-706) @ -5 °C
(85000 psi) Class
High tensile
80-95 3.6 (35)
SECTION 12 APPENDIX
steel 80 kgf/mm2 0.16 0.15-0.55 1.60 0.03 0.03 0.60-1.20 0.30-0.18 70 (686) (784-931) @ -15 °C
(115000 psi) Class
S35C (JIS) 0.32-0.38 0.15-0.35 0.60-0.90 0.03 0.035 0.20 0.20 40 (392) 58 (568)
1035 (AISI) 0.32-0.38 - 0.60-0.90 0.03 0.050 - -
SECTION 12 APPENDIX
12-5. Specifications of Shield Arc Electrodes for Mild Steel
Mechanical properties
Type of Welding Tensile Yield point Elongation Temperature Impact
JIS AWS Electric power strength N/mm2 % °C value
coating flux position
N/mm2 (kgf/mm2) (°F) J
(kgf/mm2) (kgf·m)
E4303 E6013 Lime-titania F, V, O, H AC or DC (±) 0 27
20 ( 2.8)
E4311 E6011 High cellulose F, V, O, H AC or DC (+) -30
E4312 E6012
High titania F, V, O, H AC or DC (±) 16 - -
E4313 E6013
27
E4316H15
( 2.8)
E7016 Low hydrogen F, V, O, H AC or DC (+) 16 -30
47
E4316UH15
( 4.8)
27
E4319
430 330 ( 2.8)
E7016 ilmenite F, V, O, H AC or DC (±) 20 -20
( 44) ( 34) 47
E4319U
( 4.8)
Iron powder
E4324 E7024 F, H AC or DC (±) 16 - -
titania
27
E4327 E6027 Iron powder F, H AC or DC (-) 20 -30
( 2.8)
Iron powder-
E4328 E7028 F, H AC or DC (±) - - -
Low hydrogen
F, V, O, H, or 27
E4340 E7024 Special AC or DC (±) 20 0
any posture ( 2.8)
fNOTE: 1. The alphabet in the column ” Position of weld” stands for the followings.
F: Downward Position V: Vertical Position O: Overhead Position
H: Horizontal Position or Horizontal fillet welding
The position of weld shown above is applied when the electrode diameter is smaller than 5 mm (0.2 in).
2. Horizontal fillet welding is applied for JIS E4324, E4326 and equivalent.
3. The alphabet in the column ” Electric power” stands for the followings.
AC: Alternating current DC (±): Direct current, electrode (+) or (-)
DC (+): Direct current, electrode (+) DC (-): Direct current, electrode (-)
4. Even if yield point and tensile strength decrease 9.8 N/mm2 every 2% increase of elongation, it is allowable in JIS
E4327 or equivalent on condition that yield point is 320 N/mm2 or up and tensile strength is 400 N/mm2 or up.
12-5
SECTION 12 APPENDIX
12-6. Specifications of Shield Arc Electrodes for High Tensile Strength Steel
Tensile Yield point Elongation Temperature Impact
Type of Welding Electric
JIS AWS strength N/mm2 % °C value
coating flux position power
(kgf/mm2) (kgf·m)
47
E4903 E6013 Lime-titania F, V, O, H AC or DC (±) 0
( 4.8)
27
E4916H15 E7016
( 2.8)
Low hydrogen F, V, O, H AC or DC (+) -30
490 400 47
E4916UH15 E7016 20
( 50) ( 41) ( 4.8)
27
E4919 E6019
( 2.8)
ilmenite F, V, O, H AC or DC (±) -20
47
E4919U E6019
( 4.8)
E5516-GH10 E7016 550 460 - -

17
( 56) ( 47)
27
E5716H10 E7016
( 2.8)
570 490 47
E5716UH10 - 16
( 58) ( 50) ( 4.8)
27
E5716-H10 -
( 2.8)
E5716-UH10 E8018-W2
-20
E6216-3M2UH10 E9016-G
E6216-N1M1UH10 E9016-G 620 530
E6216-N2M1UH10 E9016-G 15
( 63) ( 54) 47
E6218-N1M1UH10 E9018-G Low hydrogen F, V, O, H AC or DC (+) ( 4.8)
E6218-N2M1UH10 E9018-G
E6916-N3CM1UH10 E10016-G
E6916-N4M3UH10 E10016-G 690 600
14
( 70) ( 61)
E6916-GH10 E10016-G - -
E7616-GH5 E11016-G 760 670 - -

( 77) ( 68)
E7816-GH5 E10016-G - -
E7816-N4C2M1UH5 E10016-G -40 -
13
E7816-N4CM2UH5 E10016-G 780 690 -
-20
E7816-N5CM3UH5 E10016-G ( 79) ( 70) -
E7816-N5M4UH5 E10016-G -60 -
E7816-N9M3UH5 E10016-G -80 -
12-6
SECTION 12 APPENDIX
Tensile Yield point Elongation Temperature Impact
Type of Welding Electric
JIS AWS strength N/mm2 % °C value
coating flux position power
(kgf/mm2) (kgf·m)
27
E4928H15 E7018
490 400 ( 2.8)
20 -30
( 50) ( 41) 47
E4928UH15 E7018
( 4.8)
27
E5728H10 -
Iron powder- ( 2.8)
F, H AC or DC (+)
Low hydrogen 47
E5728UH10 -
570 490 ( 4.8)
16 -20
( 58) ( 50) 27
E5728H10 -
( 2.8)
47
E5728UH10 -
( 4.8)
fNOTE: 1. The alphabet in the column ” Position of weld” stands for the followings.
F: Downward Position V: Vertical Position O: Overhead Position
H: Horizontal Position or Horizontal fillet welding
The position of weld shown above is applied when the electrode diameter is smaller than 5 mm (0.2 in).
2. The alphabet in the column ”Electric power” stands for the followings.
AC: Alternating current DC (±): Direct current, electrode (+) or (-)
DC (+): Direct current, electrode (+) DC (-): Direct current, electrode(-)
12-7
SECTION 12 APPENDIX
12-7. Estimation Formula of Preheat

Temperature
The following estimation formula is used to decide preheat
temperature necessary to prevent the occurrence of cold
cracks.
PHK=(2.03 PW-0.55)×103 (°C).................................................................................... [1]
<Double-Bevel, Single-J, and Single-Bevel Groove Weld>
PHY=(1.33 PW-0.38)×103 (°C)................................................................................... [2]
<Double-Vee, Single-Vee, and Single-U Groove Weld>
Where:
Pw: Weld-crack-sensitivity index shown in the following
formulas.
PW=PCM+H/60+K/40000 (%)................................................................................... [3]
PCM=C+Si/30+Mn/20+Cu/20+Ni/60+Cr/20+Mo/15+V/10+5B (%)
.................................... [4]
C, Si, Mn, Cu, Ni, Cr, Mo, V, B: Alloy elements (Weight %)
H : Diffusive hydrogen (cm3/100 g) .......... value measured by quenching method
K : Constraint degree of weld joint ( kg/mm2·mm )
The formula Pw is applicable when the chemical compositions

of the base metal are within the ranges shown in the following
table.
C 0.07-0.22 % Si 0.00-0.60 % Mn 0.40-1.40 %

Cu 0.00-0.50 Ni 0.00-1.20 Cr 0.00-1.20
Mo 0.00-0.70 V 0.00-0.12 Ti 0.00-0.05
Nb 0.00-0.04 B 0.00-0.005
Plate Thickness (t) : 19 to 50 mm (0.7 to 2 in)
Constraint Degree (K) : 500 to 3300 kg/mm2·mm
Volume of Hydrogen (H) : 1.0 to 5.0 cm3/100 g
12-8
SECTION 12 APPENDIX
12-8. Crack Report

When a crack is found, download the Crack Report format using e-Cabinet (Identifier No.GM00001534) and use it. Fill in
the required items while referring to the Crack Report example on the next page and attach it to the Service Information
System (FIR: Field Information Report). The following four items are required in the Crack Report.
(1) Stamping serial number

For the stamping position of the serial number for each structure, refer to pages 12-10 to 12-11 for excavators and
page 12-13 for dump trucks.
Hitachi Construction Machinery Co., Ltd. manages the structures based on serial numbers. Therefore, it is possible to
check the manufacturing time etc. based on the serial number and take appropriate measures.
(2) Photo of overall machine
The field situation and machine status can be checked.
(3) Information of crack position
Provide the information on the crack position using photos and illustrations. Depending on the crack position, it may
not be possible to determine the crack position from only the photos, and it may take more time to confirm.
(4) Photos of crack details
Provide overall photos and enlarged photos including dimensions of the crack. And, when the crack has spread to the
side or inside, attach photos of it in the same way. This information can make appropriate measures take.
12-9
SECTION 12 APPENDIX
 Example of Crack Report for Excavators
(1) Stamping serial number

(For the stamping position,
refer to pages 12-10 to 12-
11.)
(3) Information of crack position

Illustrations of the crack
position

Photos of the starting point,
distance and dimensions of
the crack

Enlarged photos that the
position can be seen

When the crack has spread
to the side or back, attach
photos of it.
RW-12-01-001E
12-10
SECTION 12 APPENDIX
 Stamping Position of Serial Number for Excavators (1/2)
RW-12-01-002E
fNOTE: The stamping position of serial number may vary

depending on the model.
12-11
SECTION 12 APPENDIX
 Stamping Position of Serial Number for Excavators (2/2)
RW-12-01-003E

12-12
SECTION 12 APPENDIX
 Example of Crack Report for Dump Trucks
(1) Stamp of serial number

(For the stamping position,
refer to page 12-13.)

Enlarged photos that the
position can be seen
(3) Information of crack

position
Illustrations of the crack
position

Photos of the starting point,
distance and dimensions of
the crack
RW-12-01-004E
12-13
SECTION 12 APPENDIX
 Stamping Position of Serial Number for Dump Trucks
RW-12-01-005E

12-14
SECTION 12 APPENDIX
12-9. Weld Terms
Terms Definition
A
Actual throat Throat actually welded. The shortest distance from the root to the surface of a
(- of a fillet weld) section of the fillet weld.
Actual throat Theoretical throat
Theoretical
Actual throat
throat
Size Size
Leg Leg
RW-12-09-008
Arc air gouging Method of grooving on metal surface by continuously blowing metal melted with
arc heat with compressed air.
Arc strike To generate arc first or to generate arc instantaneously on base metal and then
immediately cut it in arc welding.
Arc welding Welding performed with arc heat.
B
Back chipping To chip from the back the part of poor penetration at the bottom of groove or the
first layer in butt welding.
Backhand welding Welding in which the progressing direction of welding is opposite to the direction
of the torch of gun.
Backing plate Material to align the bottom of the groove from the back.
(backing metal)
Blowhole Globular or nearly globular cavity caused in deposited metal.
Both side welding Welding performed from both sides; front and back.
(- of butt joint)
RW-12-09-020
Burn through Dropping of molten metal to the opposite side of groove.
Butt joint Weld joints in which the base metals lie nearly in the same plane.
Butt welding Welding used to butt joints.
Buttering To provide surfacing on the groove surface in order to prevent influence from
base metal in butt welding.
12-15
SECTION 12 APPENDIX
Terms Definition
C
Cladding by welding Process in which metal of required structure and dimensions is deposited on the
base metal surface, depending on the purpose, such as hardening, corrosion
resistance, repair, or regeneration.
CO2 gas shielded arc Automatic or semiautomatic welding performed in an atmosphere of mainly
welding carbon dioxide (CO2).
Cold crack Generic term for cracks caused after weld has been cooled near the ordinary
temperature after being welded. Under bead crack, toe crack, etc. are included in
this type of crack.
Complete joint penetration, Penetration over the entire area of the plate thickness of joint.
full penetration
Core diameter Diameter of the core wire of covered electrode.
Core wire Metal wire in a covered electrode.
Crater Indents caused at the end of bead.
D
Deposited metal Metal deposited on base metal from filler metal by the welding operation.
Deposition efficiency Ratio of mass of deposited metal to mass of consumed welding electrode,
provided that the unused part of the electrode should be restricted.
For a covered electrode, the mass of the cover is usually included, but excluded in
special cases.
Deposition rate Mass of deposited metal put per unit time.
Droplet Particles of molten metal transferring from the tip of welding electrode to base
metal.
F
Filler metal (material) Metal (material) to be melted and added in order to make a deposited metal.
Fillet weld Welding forming a triangular section to weld two faces intersecting nearly
orthogonally in lap joints, T joints, cross-shaped joints and corner joints, etc.
Fish eye Silver white defect like fish eye which appears on a fracture of the deposited
metal.
Flux cored wire Wire for welding in the form of a pipe, in which flux is filled for the purpose of arc
stabilization and deoxidation.
Forehand welding Welding in which the progressing direction of welding coincides with the
direction of the torch or gun.
12-16
SECTION 12 APPENDIX
Terms Definition
G
Gas cutting Cutting performed by utilizing the rapid chemical reaction between the metal
and the oxygen generated by heating with a gas flame. Generic term of oxygen-
acetylene cutting, oxygen-hydrogen cutting, oxygen-propane cutting and
oxygen-natural gas cutting, etc.
Gas gouging Grooving using gas flame and oxygen.
Groove Groove provided between base metal to be used.
Groove angle θ ° in Figs. below.

θ
RW-12-09-003
d
Groove depth d in Figs. below.
RW-12-09-004
H
Hand welding, manual Welding where welding operation is performed by hand.
welding
Hardfacing Deposition of hard metal layer on base metal surface so that the base metal can
resist wear.
Heat input Heat quantity given to weld from outside in welding.
Heat-affected zone Unmelted zone whose base metal structure and mechanical properties have been
changed by the heat of welding and cutting.
Hot crack Cracks caused under elevated temperature, such as within the range of solidifying
temperature of the weld or immediately below it.
I
Intermittent fillet weld Fillet weld where the welded parts and unwelded parts alternately exist.
RW-12-09-010
12-17
SECTION 12 APPENDIX
Terms Definition
I
Interpass temperature, Lowest temperature of pass before the next pass starts in multipass welding.
(Interlayer temperature) Interpass temperature for one layer per one pass is called interlayer temperature.
L
Lack of fusion, incomplete Condition in which welding boundary faces are not sufficiently fused with each
fusion other.
Lack of fusion
RW-12-09-016
Lack of penetration, Causing the unpenetrated portion in full penetration weld joint.
incomplete penetration
Lack of penetration Lack of penetration
RW-12-09-013
Leg Distance from root of joint to the toe of the fillet weld.
(- of a fillet weld) When used in design, the dimension of size is sometimes called by this name.
Leg
Leg
RW-12-09-006
Longitudinal crack Crack nearly parallel to the direction of bead caused on bead or its heat-affected
zone.
RW-12-09-009
M
Melting rate Speed at which the welding rod melts per unit time.
Mold welding Welding in final layer of cladding using the electrode which forms smoother
welding beads.
Molten pool Place where molten part appears like a pool due to heat of arc in welding.
Multi-layer welding Welding to lap beads to multiple layers.
N
Non-distructive testing Any testing method which does not involve damaging or destroying the test
sample; include use of X-rays, ultrasonics, magnetic flux, and so on.
12-18
SECTION 12 APPENDIX
Terms Definition
O
One side welding Welding performed from only one side of butt joint.
(- of butt joint)
RW-12-09-005
Overlap Lapped portion of deposited metal without being fused with base metal at the
toe.
Overlap Overlap
RW-12-09-002
P
Partial joint penetration Penetration that is not prevailing on the entire area of the plate thickness of joint.
Partial joint
RW-12-09-015
Peening Operation to provide plastic deformation on the surface layer by continuously

hitting the weld with a special hammer.
Penetration Distance between the summit of molten part of base metal and the surface of the
plane to be welded. Penetration
Penetration
Penetration
Penetration
RW-12-09-012
Penetration bead Bead of regular waveform caused at opposite side (back) of the electrode in one
side welding.
Plug welding Welding in which holes are bored in one of the base metals to weld fully from the
surface of plate to the other base metal.
Porosity Group of small blowholes in deposited metal.
12-19
SECTION 12 APPENDIX
Terms Definition
P
Postheating Application of heat afterward to weld or gas cutting zone.
Preheating Application of heat to base metal prior to operation in welding or gas cutting.
Preset distortion Distortion given in inverse direction by predicting angular and other deformation
resulting from welding.
R
Reinforcement of weld Deposited metal piled out of surface more than required dimension in groove or
fillet weld. Reinforcement
Repair welding Welding to repair defects, and incorrect dimensions and shape. RW-12-09-019
Residual stress Stress remaining in structures or members.
Root face b in Figs. right.
Root gap a in Figs. right. Root Root

RW-12-10-001E
S
Semi-automatic arc welding Arc welding performed by using equipment that automatically feeds wire while
operating the torch manually.
Shielded metal arc welding Welding performed by using covered electrodes.
Slag Nonmetallic substances caused on the weld.
Slag inclusion Remaining of slag in deposited metal or fused zone with base metal.
Solid wire Wire, for welding, the section of which is solid and homogeneous.
Spatter Slag and metal particles scattering during welding in arc welding and gas
welding.
Surfacing Generic term for method in which metal is deposited on a base metal surface,
such as cladding by welding or thermal spraying.
T
Tack welding Intermittent positioning welding for holding base metal at a definite position
prior to regular welding.
Theoretical throat Throat used in design calculation. Height of triangular fillet determined by the
(- of a fillet weld) size of the fillet measured from the root of the joint.
(Refer to the figure in “actual throat”.)
Throat Refer to “actual throat”.

(- of a fillet weld)
12-20
SECTION 12 APPENDIX
Terms Definition
T
Toe Point at which base metal surface and welding bead surface intersect.
a b
c d e
RW-12-09-007
Toe crack Cracks caused at the toe of weld.
Torch, blowpipe Apparatus used to heat, weld, and cut metal and other material by using
gas flame, argon arc, plasma arc, etc. Called welding torch, cutting torch, etc.
depending on the application.
Transversal crack Cracks nearly perpendicular to the direction of bead caused on bead or its heat-
affected zone.
RW-12-09-018
U
Under-bead crack Internal cracks caused near the bead.
RW-12-09-014
Undercut A portion remaining as a gulf without being filled with deposited metal after base
metal has been sunk along the toe of the welding.
RW-12-09-001
V
Voltage reducing device Equipment to prevent electric stroke by lowering the secondary no-load voltage
of welding machine when arc is not generated in arc welding.
12-21
SECTION 12 APPENDIX
Terms Definition
W
Weld line Assumed line for expressing the bead and weld as a line.
Weld metal Metal melted and solidified during welding, a part of the weld.
Heat affected zone
Weld metal
RW-12-09-017
Welding current Current required to flow in order to give the required heat for welding.
Welding distortion Deformation caused in members by welding.
Welding position Position taken by welding operator against weld.

This includes four positions; flat, horizontal, vertical, and overhead positions.
Welding speed Speed of welding bead. Usually expressed by bead length per minute.
Welding symbol Symbol for giving designation for welding on a drawing.
Wire extension Extending length of welding wire from the end of contact tube or tip.
Wire extension
Arc length
RW-12-09-011
12-22
Progress and Deliberation
History of this manual

From around 1989, early cracks in the structure became a problem in EX1800 and EX3500. At that time, in addition to
improving product quality, materials such as crack check sheets used on site were also maintained. On the other hand,
since it was recognized that it was important to provide on-site workers guidance on welding work when implementing
countermeasures against cracks, the contents of the welding work were summarized in this manual.
Revision history
REV. Date of issue Page Remarks Consultation department and members
0 Jun. 1, 1994 All First edition issued -
1 Sep. 30, 2019 All Mainly changed the following contents. • Service Material Development Center:
• Review and enhancement of welding K. Naruse, J. Ishikawa
related standards. • Mining Development & Production Div.:
• Added description about post heat and M. Ebisawa
cast steel. • Structure Production Engineering Dept.:
• Delete BS standard. H. Sakamoto
• Added "Progress and Deliberation“. • Global Production & Procurement Strategy Office:
i. Aizawa, K. Koyanagi
• Tsuchiura Production Dept.:
H. Sumiya
• Global Quality Strategy Dept.:
O. Ootaki
• Mining Sales and Service Div.:
H. Tanaka, K. Uno
Revision of this manual

For revision of this manual, please contact PM document group of Service Material Development Center, CS Division, LS
Headquarters.
Progress and Deliberation

Ko-111-01 Repair Welding+Manual e (20201207)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ko-111-01 Repair Welding+Manual e (20201207)

Uploaded by

Copyright:

Available Formats

PART NO.

REPAIR WELDING MANUAL

PRINTED IN JAPAN (K) 2019, 09

 This manual describes repair welding for mining machine structures.

How to Use This Manual

 When performing repair welding work:

CAUTION DON’T: DON’T:

yellow pages blue blue

 When any questions on the method or details of repair welding arise:

All information, illustrations and

Safety Precautions for Repair Welding Work

 Wear protective clothing

 Use tools and equipments appropriate for the work to be SA-437

 Protect against hazardous light rays and hot metal splatters

 Protect against noise

Precautions for Welding and Heating

 Avoid potentially toxic fumes and dust.

 Remove paint before welding or heating

 When welding or heating in an enclosed area, be sure to

 Pressurized pipes and hoses can be accidentally bursted

 Before starting to weld or using a torch, thoroughly clean

Cautions to be Taken While Welding and Heating

 Avoid welding or heating by a torch around the hydraulic

 After completion of welding and heating work always check

 If the gas burner burns incompletely during preheating,

Use Handholds and Steps

Precautions for Machine Operation

 If a maintenance procedure must be performed with the

 Take precautions when operating the machine

 Be sure to remain seated in the operator's seat while

Practice Safe Repair Welding

 Prepare and clean the work area.

 Beware of exhaust fumes.

 Illuminate work area safely.

 Allow the engine and the hydraulic oil to cool before

 Disconnect the battery ground cable (-) before welding on

2-1. Don't's: Fundamentals

3-1. Don’t’s: Examples [Vise-Installed Example]

Weld here first

 DO NOT divide reinforcing plates carelessly.

RIGHT Joining plates at stress WRONG

Join reinforcing plates at low fNOTE: Stress concentrated areas in the

Small Notch Correcting with Grinder

Overlaying Finishing with Grinder

 DO NOT reinforce using ribs.

Seat Screw EX-001

 DO NOT leave bump where bead leg length changes.

 DO NOT change bead leg length at a corner.

100 mm (4”) or more Too close

 DO NOT leave any notches on gas-cut surfaces.

Grinder-Finished Surface Gas-Cut Surface

TOOLS & AUXILIARY EQUIPMENT

4-1. Tools & Auxiliary Equipment

 Fire proof cover and extinguisher

Plate thickness gauge RW-04-01-003

Thermal chalk RW-04-01-004

 Exhaust Gas Equipment, Dust Respirator

 Finishing Tool Surface Thermometer (Non-Contact) RW-04-01-008

 Exhaust Gas Equipment, Dust Respirator

Ultrasonic flaw detection device RW-04-01-005

 Reinforcing Plate Fixture

 Painting Tungsten carbide cutter RW-04-01-006

Straight grinder RW-04-01-007