HITACHI KO-111-00 REPAIR WELDING MANUALFORWARD If construction machineries work under severe con- ditions for long period, welded structural components. may crack. To reduce down time and to extend the life of the machine, itis imperative to check for cracks and to repair as soon as possible. Repairing cracks by ap- propriate welding techniques (crack detection, re- straint, preheating, gouging, repair welding, rein- forcement, and finishing) are most important and ef- fective measures. However, if inadequate repair welding is applied, cracks will develop again in a shorter period of op- eration than before, making it difficult to trace the ‘cause of the repeated crack. It appropriate welding techniques are not performed, this will allow cracks to develop repeatedly ‘+ This manual aims to introduce the correct meth- ‘od of repair welding to prevent cracks from de- veloping repeated. + This manual is intended for welders who have completed technical training of welding (Ameri- can Welding Society Class 3 or up, or equiv alent), Hitachi sales support servicemen and Hi- ‘tachi Dealer servicemen who are in the position to supervise repair welding. 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 ©1694 Hitachi Construction Machinery Co, Lid, Tokyo, Jepan Allright reservedsectiono2 |NG DON’T’S : FUNDAMENTALSDON’T’S : FUNDAMENTALS PREPARATIONS + DO NOT perform gouging work without con- firming the number, size, and location of cracks/flaws. Without knowing the cracks/flaws to be re- moved, places with no cracksiflaws detected may be removed andjor sufficient gouging depth may not be obtained in order to remove cracks/flaws. + DO NOT perform repair welding work with- out recording all confirmed data. Without having records of previous repair work, any person uninformed of the original repair work would not understand the details of the original repair work. For this reason, if a crack develops near or on the previously repaired place, the cause of the crack may not be found. + DO NOT perform repair welding without thoroughly understanding the contents of corrective and/or preventive measure draw- ings. The strength may be decreased if the reinforce- ment plate is incorrectly welded or if the re- quired grind finishing is omitted. + DO NOT perform repair welding without thoroughly understanding corrective and/or preventive measure procedure (steps). If correct steps are not followed, repairs for box type structure, i.e. inner side welding, rib weld- ing and/or crack removing, may be incompletely performed or completely hindered from being performed, + DO NOT let anyone without a proper weld ing 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 in- duced. Moreover, when removing cracks by gouging, the cracks may not be completely re- moved as the depths and directions of cracks may not be correctly located. BS-1DON’T’S : FUNDAMENTALS RESTRAINING + DO NOT perform work without setting re- straint fixtures. ‘When gouging or welding is performed, heat is generated. As base metal temperature goes down, base metal contracts, causing distortion (tip over, warp). + DO NOT use restraint fixtures that may be distorted. Weak restraint fixtures may distort and thus may not function as proper restraint fixtures. DO NOT weld a restraint fixture to machined surfaces. It a restraint fixture is welded on a machined surface, the machined surface must be ma- chined again. DO NOT attach restraint fixtures to a part having a match without confirming the di- mensions of the matching parts. It 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 di- mensions. DO NOT preheat welding material before setting required restraint fixtures. Similar to the case of welding work, as the tem- erature of preheated parts goes down, the pre- heated 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 wel preheat temperature. ing without measuring Low preheat temperature may cause cracks. High preheat temperature may cause britting 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 heat- ing area. Base metal becomes brittle and resulting distor- tion increases. BS-2DON’T’S : FUNDAMENTALS REPAIR WELDING + DO NOT ground far away from the welding part. For example, do not ground at a hydraulic cyl inder 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 pene- trated, DO NOT use a faulty holder (torch) or gas burner. Electrocution or burns may result. Also, appro- priate heating or welding cannot be done with it. + DO NOT perform gouging using a gas burn- er on high tensile strength steel or on sp cial steel. As the temperature excessively rises, base met- al becomes brittle, causing cracks. + DO NOT perform any gouging without con- firming the thickness of plate first. When the back side cannot be welded and if the plate is penetrated accidentally, uncorrect- able notches will remain. + DO NOT generate arc strikes (sparks) on places other than the welding part. ‘Arc strike parts harden. Even after grind finish- ing, cracks may appear at the bent areas of plates or rounded areas. + DO NOT weld gouging-performed parts as they are, Weld defects may be generated inside, or the welded part may become brittle. Be sure to fin- ish a gouging-performed part with grinding be- fore starting to weld on it. DO NOT use flux cored wire or coated elec- trode 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, in- appropriate bead forms may result, causing cracks. DO NOT leave any failures uncorrected. Cracks will appear in a short time after comple- tion of repair welding, DO NOT weld on high tensile strength steel or on special steel, surpassing interpass temperature. Base metal around welded parts becomes brit- tle. Also, it may cause distortion to increase. Keep interpass temperature higher than pre- heating temperature and lower than 400 °C (752°), DO NOT rapidly cool (or quench) high ten- sile strength steel or special steel. The steel may become britle. For this reason, toughness may decrease, eventually lea breakage. BS-3DON” ‘'S : FUNDAMENTALS + DO NOT perform welding work without tak- ing into account crack propaga- tion(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 distor- tion will result. DO NOT weld gas cut surfaces without grind finishing them first. Poor penetration caused by notches on out sur- face will result. Also, weld defect caused by slag inclusion may result. DO NOT close manholes without first con- firming 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, caus- ing 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 heat- ing area. Base metal becomes brittle and resulting distor- tion increases. + DO NOT perform straightening on one side only. Amount of distortion increases and distortion, rections may become mutt-dimentsonal. DO NOT heat and then rapidly cool ma- chined surfaces. Distortion will develop on machined surfaces. BS-4DON’T’S : FUNDAMENTALS REINFORCEMENT + DO NOT add reinforcing plate carelessly. It a reinforcing plate is carelessly added, it may inversely increase stress concentration, leading to the occurrence of new cracks. FINISHING + DO NOT leave finished surfaces coarser than specified, Stress concentration may result if finished sur- face is left coarse or notch(es) exist. DO NOT omit grind finishing on any speci ied areas. Atthough weld bead or ends of bead may look smooth and flat, there always are undercuts andjor overlaps, causing stress concentration. DO NOT leave any notches on finished sur- faces. 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 sur- faces. Precise dimensions cannot be obtained by grinding. For this reason, oil leakage or exces- sive wear may result BS-5Importance of Restraining Work Precautions for Restraining Work 2.02... Examples of Attaching Restraining Fixtures Precautions for Removing Restraining Fixtures. SECTION 06 RESTRAINING CONTENTS PT FX PKAMEMORESTRAINING IMPORTANCE OF RESTRAINING WORK ‘The purpose of the restraining work is to reduce dis- tortions 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 mak- ing the reassembly of them difficult or impossible, after disassembly for repair. PRECAUTIONS FOR RESTRAINING WORK * Before attaching a restraining fixture to the struc- ture, measure the dimensions of the repair section and record them to check the distortion after repair welding. * 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. ‘After checking that the tack welding was performed to the correct dimensions as indicated on the draw- ing, attach a fixture strong enough to endure against distortion. Especially, the restraining fixture used to resist against compressive distortion must have sufficient strength. (Use two L- shape-section steel bars with the dimension of 100-150 mm (4-6 in) * t 12 mm (1/2 in) to restrain distortions at the yoke bracket on the top end of the boom or arm for the EX3500 excavator size machine.) ur OS SS) wen WRONG] | RIGHT| Terai ce moose Restraining 100-150 mm (4-6") TIL «: sem aie")RESTRAINING * Attach a restraining fixture before preheating for regular welding. Preheating will also cause distor- tion when it is cooled. ‘+ Weld a restraining fixture to a space other than a machined surface. If welded to a machined surface, [WRONG] the surface must be machined again. Restraining Fixture Welding Machined Surface * When welding a restraining fixture to a high tensile strength steel or to a special alloy steel, preheating is required before welding. _ Burner Ry Zo * After completing repair welding, check the dimen- oe sions and record them.RESTRAINING EXAMPLES OF ATTACHING RESTRAINING FIXTURES ‘* Restraining fixture attached between bosses of the boom or arm. * Restraining fixtures limiting distortions on brackets of the boom, arm, and center frame. HH UU Welding Restraining Restraining Fintre Fcure 4 reces oc * Restraining the side plates, top plates, and bottom plates of the boom and arm Repair Welding Inner Fis FX-3RESTRAINING * 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 sec- tion of the rib provided inside the boom and arm, cracks may develop from that point. Thus, welding restraining fixture in this section should be avoided. RIGHT] WRONG] Restraining Fonure woes «It an arc strike impression is left at the plate fringe of the yoke bracket provided at the tip end of the RIGHT] [WRONG] boom and arm, cracks may develop from that point. Thus, welding a restraining fixture in this section should be avoided. IZ ZA 0s PRECAUTIONS FOR REMOVING RESTRAINING FIXURE ‘Smal Notch Frrish by Grinding * Be sure to remove the restraining fixture after rec- tifying distortion. Ifthe restraining fixture is removed LZ before rectifying distortion, distortion may increase into any direction. Rectifying the distortion may be difficult. Large Notch Remove Remaining * Alter removing the restraining fixture, completely re- move the weld bead by grinding. If a large notch is left, fil the notch by cladding and finish the bead surface flat with the base metal. Beads o 40-50 mm (1-1/2-2") when be base matalis ‘high tensile strength sto!: |Concave by Cladding Fiaishing by gincing YI. ——~ IZZZ. FX-4Preheating ........6265 ‘Temperature Between Welding Paths... Warming Up Postheating Selection of Preheating Temperature. Preheating Method Temperature Checking Method SECTION 07 PREHEATING CONTENTS PHA PHA PH2 PH2 PHS PH PHS By.PREHEATING PREHEATING Weld joint and its vicinity are heated to a specified tem- perature 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 un- treated 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. However, it is sometimes performed to intermediate or final 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 (60 °F), be sure to preheat base metal even if it is normally not preheated. Burner TEMPERATURE BETWEEN WELDING PATHS The base metals are heated while being welded. When a high tensile strength steel is welded, the weld metal and heat affected zone will embrittie due to welding heat. Thus, the maximum temperature between welding paths must be controlled in the range higher than pre- heating 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 preci- sion parts lke ball bearings are installed, the maximum temperature between paths is sometimes restricted to protect the precision part from deformation by heat. IMPORTANT: When temperature between weld paths is specified on the drawing or in Second Path ‘some instruction forms, be sure not to exceed the specified temperature. Fist Path DEK vy PH-1PREHEATING WARMING UP The purpose of warming up are to dehydrate the sur- face of the base metal and to warm the base metal up to normal temperature. The vicinity of the weld joint is to be heated up to approx. 40 °C (104 °F) before welding even if material of the base metal is normally not pre- heated. 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. PH-2PREHEATING SELECTION OF PREHEATING TEMPERATURE IMPORTANT: When preheating temperature is specified on the drawing or in instruc- tion forms, be sure to use the speci- fied temperature, The preheating temperature and the temperature be- tween weld paths are not selected simply by the kind of base metal. It must be selected by the estimation for- mula using factors of groove shape, chemical composi- tions in the base metal, degree of restraint, and amount of diftusive hydrogen. (Refer to “Estimate formula’ in section 12 “Appendix” ) Therefore, when performing re- pair welding, apply the specified temperature indicated on the repair drawing. Generally: * When single-bevel groove is called for, the preheat- ing 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 re- straint depends on groove shape) * The thicker the plate, the higher the preheating temperature. * Manual welding requires higher preheating tempera- ture than semi-automatic welding. The standard preheating temperatures are shown in the table below: T: Plate Thickness Weld stee! T<25 mm 25 lh tne et (122-212°F) | (158-248°F) | (212-302°F) (85.000 psi) a a Class High tensile sel 70-120°C | 100-160°C | 120-180°C nn = = 248° 302 ° ° etiam, (158-248 °F) | (212-902°F) | (248-856 °F) Class igh ena eel 100-150°C | 120-180°C | 150-200°C rn = - ° oy 3 Greedy (212-302 °F) | (248-356 °F) | (802-392 °F) lass PH-3Importance of Gouging Arc-Air Gouging Preparation for Gouging Gouging Procedure Finishing SECTION 08 GOUGING CONTENTS Go Go 60-3 Go-4 Go7GOUGING 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. (Crack Gouging ARC-AIR GOUGING 1. Kinds of Gouging Gouging methods are grouped as follows: + Arcrair gouging + Gas gouging + Plasma gouging Generally, when repairing cracks on structures for construction machineries, arc-air gouging finished by grinder is employed. 2. Characteristics of Arc-Air Gouging The reasons why arc-air gouging is mainly em- ployed 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 com- pression. GO-1GOUGING 3. Kinds of Gouging Rods Gouging rods for mild steel are as follows: Carbon Size mm (t) | Copper | Applying | Gouging Speed Groove Shape mm (i) me Diameter | Length | Coating | Current (A) | mmymin (inimin) Depth Width mm(n) 5.03/16) | 205(12) | Coated | 100-200 | 900-1 200 (25-50) |s-« (ve-si32) [7-9 (ora2-11/32) | -9(11752) 6.5 (1/4) t t 200-350 | 900-1 200 (35-50) | 4-5 (5/32-9/16) |o-11 (11/92-19/92) | -12 (15/92) sowie | t + | 250-400 | 700-1 000 (20-40) | 5-6 itera) | 10-42 @je-t8/92) | 12 (15/82)- 9.0 (3/8) t + | s00-450 | 400-700 (15-30) ]o-7 (74-8732) | 11-13 (19/82-1/2) t 11.0 (7/16) t t 400-550 | 300-400 (12.15) | 8-9 (6/16-11/32) | 13-15 (1/2-19/32) 1 43.0 (1/2) t + | 480-600 | 200.300 (6-12) } 9-10 (11/82-9/8) | 15-17 (19182-21182) t 4. Fundamental Precautions + Use a dried gouging rod. “Whenever a gouging rod comes in contact with steel, arc will appear. Protect the environment from damage. + Connest the torch holder to the positive terminal of the D.C. machine. + Extend the gouging rod approx. 150 mm (6 in) from the holder head. - Tilt the gouging rod approx. 45 °. As soon as arc appears, blow air and move the gouging rod for- ward. Maintain air pressure within 6 to 7 kgffom? (85 to 100 psi). If air pressure becomes lower than 4 katfom? (65 psi), 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 from propagating. (Refer to “Removal and repair of weld defect” in section0s “Repair Welding") Carbon Electrode Ar Valve Handle GO-2GOUGING PREPARATION FOR GOUGING Perform the following preparation before gouging. (1) Check plate thickness and material by referring to drawing. (2) Check crack length and depth by ultrasonic flaw detection method or liquid penetrant inspection (Dye check) method. (8) Be sure to remove rust, paint, oll, ete. adhering to the gouged area. 5 [WRONG| (4) Gouging will produce sparks. Keep inflammables away from the gouging area. ALIN nae Fite Proot Cover (6) 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. Hydraule Cynder IMPORTANT: When ambient temperature is below 20 an % 10 °C (50 °F), warm up the base metal to 30 to 50 °C (86 to 122 °F) even if it TSS is mild steel. coor GO-3GOUGING GOUGING PROCEDURE 1. General Instructions + Avoid gouging work inside a box-section structure for workers safety and to increase work efficiency. “Decide the direction of gouging so that upward welding can be reduced as much as possible. + After gouging, finish the gouging surface by grind- ing to remove carbon deposits. Before welding, be sure to check that cracks are Ae completely removed by the liquid penetrant in- spection (Dye check). LJ coon 2. When crack has not broken through yet: + Gouge the crack so that 4 mm (5/32 in) or more bottom thickness is left. 4 mm_ (5/32 in) bottom thickness is not 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 « so that torch angle and elec- 4mm (/82") trode angle can meet properly ormore GO-4GOUGING 3. When crack has broken through: NOTE: Be sure to’ check that cracks have broken through by a reliable inspection method such as ultrasonic flaw detection inspection. + When plate thickness is 19 mm (3/4 in) or less: = Gouge the crack so that 4 mm (5/32 in) or more bottom thickness is left. Make groove angle a so that torch angle and elec- trode angle can meet properly. ‘After welding the front side, gouge the reverse side 3 mm (1/8 in) or more. + 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 increased, leading to possible distortion. = Make groove angle ap and ay so that torch angle and electrode angle can meet properly. 3mm (1/8") am" ‘ . ve") t ‘Simm (1/8) GO-5GOUGING 4.When weld joint with a backing plate is cracked: “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 « so that torch angle and elec- trode angle can meet propery. GO-4GOUGING FINISHING ‘Gouged Surtace ‘After gouging, grind the gouging surface to remove car- bon adhering to the gouging surface and to smoothly finish the surtace. Grinding work is required to com- pletely remove melted slag or carbon adhering to the ‘gouged surface. Otherwise, they will cause weld defects ‘such as an incomplete fusion. Surface Finished by Grinding Remove section shown Generally, an angle grinder (disc grinder) is used. How- with EBS by grinding, ever, a pencil grinder is used to finish such a section as ‘a groove root face where an angle grinder is difficult to apply. ‘Angle Grinder Pencil Grinder GO-7Welding Steel. Electrode Drying of Electrode Cleaning of Weld Section Before Welding Welding Current Welding Speed Tack Welding Dimensoins of Weld Joints. Precautions for Using Backing Plates Temporarily Welding of Supplementary Parts. Weld Distortions Prevention of Weld Distortions... Types of Weld Defects Major Types of Weld Defects and Their Causes ..... Weld Defect Check ........2.005 Visual in Spection Standards for Weld Joint Removal and Repair of Weld Defect Correction of Weld Distortions peprneen Inspection After Repairing Weld Defects Precautions for Semi-Automatic Welding ...... SECTION 09 REPAIR WELDING CONTENTS wo-1 wo-2 wo-5 wWD-6 wo-6 WD-7 wo-7 Wo-10 wo-12 wo-13 wo-14 wo-15 wo-18 wo-19 wo-2t wp-21 wp-22 WD-23 wo-24REPAIR WELDING WELDING STEEL ‘Major kinds of steels used for manufacturing the Hitachi Construction Machineries are as follows: * Rolled steels for general structure (mild steel) JIS $S400, ASTM 36, BS 408 * Rolled steels for welded structure JIS $M490, ASTM 70, BS 50B JIS $M570, ASTM—, BS 55C * High tensile strength steels ‘50kgf/mm: (70 000 psi) class 60kgt/mm? (85 000 psi) class * Carbon steels for machine structure use sss. JIS S35C, AIS! 1035, BS 080A35 *High tensile strength carbon steel castings and low alloy steel castings for structual purpose (Low man- ganese cast steels) : JIS SCM2b, ASTM 90-60, BS— IMPORTANT: je sure to only use materials recom- mended by Hitachi when repairing Hi- tachi machines. The reasons why the materials recommended by Hitachi must be used: 1. When welded under a specified condition, welding structural steels are of excellent weldability, retain- ing no defect and having high mechanical proper- ties in weld zone, 2. Welding structural steels are preferable to those steels that have as low of a carbon content as pos- sible. Carbon is one of the most influential elements to control 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 cooled quickly, causing cracks and reducing ductility in the weld zone, ooee NOTE: JIS : Japanese industrial Standard ASTM: American Society of Testing and Material AISI: American Iron and Stee! Institute BS: British Standard Heat Atoctad Zone Foted Src of Bao Mata roe Hares | fore hott Masi Harness 209 Nie eo] \Quacness 77 | 200 «0 = ase Meal =} — Weld Metal 0 ol ° eres © Distance res Bond md ‘Structure and Hardness of Weld Jit High Tensile Strength Steck SW480A) ‘WD-1REPAIR WELDING 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 High Tensile Stee! ‘80 kglmm? (115 000 psi) High Tensile Stee! 60 kg/mm? (85 000 psi) D 5016 4316 D 5016 E 70166 E7016 E7016G E4302 B(H) E5102 B(H) | £4302 B(H) E5102 B(H) 100-150 150-200 (122-176) | (212-302) (302-392) Not required D 5016 E7016 E7016 E 4302 B(H) | E5102 B(H) 50-80 (122-176) 05016 100-150 (212-302) £7016G E5102 B(H) (Alsi) o80A35 100-150 150~200 (8s) (212-302) a (302-392) 4316 D5016 High Tensile E7016 E 70166 Stee! E4302 B(H) | E 5102 B(H) 60 kgimm? class 100-150 150-200 (212-302) (302-392) D416 D 5016 Daoie High Tensile E7016 E 70166 E 110166 Steel £4902 B(H) | £5102 B(H) - 150-200 (302-392) NOTE: JIS ; Japanese Standard ASTM: American Society of Testing and Material AISI. : American Iron and Stee! institute AWS. : American Welding Society BS: British Standard wo-4REPAIR WELDING DRYING OF ELECTRODES Normally, a low hydrogen type electrode is used for re~ pairing 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 al- lowing weld defects like blowholes to develop. There- fore, 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 (672-752 °F) for 30 to 60 minutes be- fore welding. Depending on the brands of electrodes, ees drying temperatures are specified. Thus, be sure to dry them in accordance with their specifications. Ifthe elec- trodes are not used soon after being dried, keep them in a container maintained at 100 to 150 °C. (212-902 °F) and use as needed. Take care not leave them out of the dyer for more than two to four hours. Aa Never ty to dry electrodes using gas burner flame. ‘Applying gas burner flame will humidity electrodes. C7 p Standard drying conditions are as follows: Humidty Range Drying Drying Time Kinds of Stee!| Electrode | Requiring Dying | vis | aws | Bs — |remperature°c ¢F) | (nin e) tow carbon | timinte Type 23 D 4301 4320 AR ‘ ions 30~60 terpaown | sas [oe] eve [ewowarn] 20503 | aoe High Tensile | LowHyarogen | =05 |psorelevoiea|esiozaqn| 00-400 a Strength Type BI] 72760) Steel D586 00-400 Desid| cowl (672.752) ae WD-5REPAIR WELDING CLEANING OF WELD SECTION BEFORE WELDING Adherence of rust, paint, oll, 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 @ gas burner is an effective measure to re- move foreign matter from the weld sections. IMPORTANT: While welding, sparks will fly. Always keep Inflammables away from the vi- cinity of the welding work site before starting welding. WELDING CURRENT Improper welding current may be a cause of weld de- fects. Thus, welding current must be determined with extra care. Amount of welding current is mainly deter- mined by the diameter of the electrode used, taking the positioning of weld and the type of the electrode used in- to consideration. ‘When thick plates are welded or the position of weld is 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. JIS D4316 (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 a positioning 100-140 A 140-190 A 190-250 A 260-320 A range Vertical or overhead positioning oe 120-180 A 160-210 A ‘WD-6REPAIR WELDING WELDING SPEED Welding speed of a shielded arc welding electrode will be greatly affected by the welder's skil, However, weld- ing too fast will reduce joint penetration and too slowly will cause poor appearance of weld beads due to enfold- ing slags and forming an uneven surface of weld beads. fj Tootess uy Poor penetration Too sow Erfolg slags 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 component, to hold welding members in position, or to keep their correct groove dimentions for regular welding. Therefore, minimum amounts and ‘numbers of tack weld beads are recommended. 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 excessive hardening of the base metals and occurrence of weld cracks. Butt Welding 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. Use strongbacks or falling stoppers to prevent misalignment or distortion of the welded members Plate Thickness mm (r)| Bead Length mm (in) | Pitch mm (n) =4(582") 1098") 250 (10") 4.28 (1/8-1") 40 (1-1/2") 500 (20") 2a (try 70(2-9)8") 800 (31°) 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. NOTE: Normally, the diameter of the tack weld electrode ‘hal be 4mm (6/82") or ess. Example of Butt Setting Piece Example of Spacer WD-7REPAIR WELDING 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 tem- peratures 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 2 ae no dserepancy atthe rot edge i found Sa 3, Remove rust, oil, etc. from on the groove faces or their vicinity before performing tack welding. k oo RIGHT] [WRONG] 4. Avoid tack welding to the weld joint comer, end face, and from the ends as shown below. som 2" WRONG] RIGHT] [WRONG] RIGHT] 5. When performing tack welding to welding lines for “Tack Welding intermittent fillet welding, take care not to weld the WRONGI places where no regular weld is required. 4 RIGHT] “Tack Welding wots WD-8REPAIR WELDING 6. When specified, tack welding beads placed on im- portant weld joints must be removed completely, just before the regular welding, 7. When temporarily-attached parts attached to the base metal by tack welding are dislocated, remove the tack-welding beads completely first. Then, re- pair the surface with cladding, and finish the sur- face until the bead surface becomes even with the base metal. (Refer to the group for ‘welding of the temporarily-attached parts") Weld Bead Chipping fl + Tack Welding res? ‘Small Notch Repairing by grinder Removing by Finishing by Large Notch ——_ginder-oOladding-+ gfnder + BEA Z 49 10 50 mm (1-722) (igh Tense Srength Stee) yoo9 ‘WD-9REPAIR WELDING DIMENSIONS OF WELD JOINTS Shapes of weld joints shall be selected depending on kinds of welded structures, welding purpose, and weld- ing methods. IMPORTANT: When the dimensions of weld joint are Indicated on the repair drawings, be ‘sure to apply them. (1) Fillet Weld Joint Throat Thickness ‘The dimensions of fillet weld joint are shown in the right figure. Fal L If lag size is not specified in drawing ; Leg size L=0.7 ty wee Leg Size a ace Root (2) Butt Weld Joint ‘The dimensions of butt weld joint are as follo @: Groove Angle c: Groove Depth ®: Bevel Angle F: Groove Radius a: Root Gap b: Root Face Uitcam beet lslels] J. - 12} chipping segev Pequed ohsfichahskrhba LJ beste Bate Feared bff lf ne ecole er gard L Ls sate mci ‘WD-10REPAIR WELDING 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 plates. If the root gap should be too wide to modify, replaced the base metal with a correct one. 56mm (an6-518" Remove all backing plates aftr welding ‘overlaying Finish the surface (Claddngby with agrinder 6 ermm (6/8")ol] oS] OW) 40] Nf os] d] ww) ss] | wus SSeUOIY eel (wool) Auofu-By wu) ( uur ) uy enren edu | yiBuens ausue, | sons jooid 10 syulod pje1A % suonisoduioo eae 1981s Jo punt ‘TaaLS ONIGTAM 4O SAILHAdOUd TWOINVHOAW AP-4APPENDIX ‘dn 40 ,wuu/N OOF | yiBuexs eysue} pue dn 40 ,WUWH/N) OZE $1 340d pyelA Jey) UONIpUCO Uo jUEFeAINbe 40 22800 SIP Ul eIgeMO|e 6} i! ‘uoREBUCIS Jo eSBALOU! 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" ‘ ez) | we | Ges) | oe (#00 ov worn] evencun|annuozera och re) 2 | Ge | ea a 7 = ae | a ee | (#1000 0¥ HOAs ewoun] voces sera (aun) (uy | 9% | quant | “usu f win | isuene ny Bunooo onjea oeduy hronebuora| wed pm | e1evel send 21083 onsod BupreN, oodky sa | sw | sir SRT EON 7AALS CTW HO4 S300YL0373 OHV GTIIHS 4O SNOILVOISIOAdS: AP-5APPENDIX (—Jepoxoeje uexino yooud (—) 90 (+) epo.nss yueuino yeIG :(+) 00 (—) 40 (+) apoxoaye ‘uauno joaug :(F) OG jeune BuyeUseyly -OV “sBuymoyjoj 84) 40} SPUBIS ,J6MOd 91:398/7 , UUINIOO EY) UJ JEqeYd/e YL “WL ¢ UBYA Je;/EWIS S| Je}eLWEIP eposoe/o OY) VEYM peridde S| eAoge UMOYS pjam JO UOHISOM BY, ‘Buypjem remy jeIUOzZUOH 40 UOHSOe [ERUOZUOH :H UORIS0d PBELLEAD {0 UONSOd [EMEA A UOMIS0d PJEMUMOC =} “SBulMo|jO} 84f 10} SPUBIS PJBM JO UORISOd , UUUNIOO ALA UI JeqeYdIe EYL “tL ALON Oey | ne repods] — ~ | ovcsa = (oa 8 ov worns Gye) | oz rpeeds| szoisa | - | oo0sa Gree | gs aaa ae ‘s-) | #2 man joeioea | ozesa es veto ore) | oe (a0 ov ea} “Bomeime] —— | petoea | szesa (v2) = Lez bade ‘981023 | 9z0sa @rz)r= = ss nee | ove veoh nor oo10ea | otesa Ge | we (oa0ov woraca| ve60ntumer] —- — [ooioea | oresa oe | we vabonpky nor] (ia201s3 fooieca | s1osa Sr | we oa. ov worn] evenoun|iuduzorsa] - | eoosa eye, | ae (00% ov Worn owoun| veorsa | — | soosa wp) | i “iN x B00 ener toedul poneGuor] wed piera | orsueL emod 190913 Logisod BupIeM, yoodky sa smv | sit ‘sojodoud jeoueyooy ‘TaALS HLONAYLS STISN3L HDIH HOS SAGOWLI3TS DUV GTSIHS 4O SNOLLVOISIDAdS: AP-6APPENDIX ESTIMATION FORMULA OF PREHEAT TEMPERATURE The following estimation formula is used to decide preheat temperature necessary to prevent the occur- rence of cold cracks. Pwue=( 2.03PW-0.55)x10° (°C) sees i Par=( 1.33Pw-0.38)x10° (°C) a Where: Pw: Weld-crack-sensitivity index shown in the following formulas. BecPee (60H) 40000 (Wi oy Pou=C+Si / 90+Mn / 20+Cu | 20+Ni / 60+Cr / 20+Mo | 15+V/ 10+5B (9%) (4) C, Si, Mn, Cu, Ni, Cr, Mo, V, B: Alloy elements (Weight 9%) Diffusive hydrogen (om?/100g)_........ value measured by quenching method. Constraint degree of weld joint (kg / mm?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__[ _0.00-4.20 Cr_| 000-120 Mo | _0.00-0.70 Vv 0:00-0:12 Ti (0.00-0.05 Nb_ [| 0.00-0.04 B (0.00-0.005 Plate Thickness (t) : 1910.50 mm Constraint Degree (Kk): 500 to 3.300 kg / mm*mm Volume of Hydrogen (H) 1.00 5.0 om? / 100g AP-7APPENDIX ‘CRACK REPORT (BACKHOE) CRACK REPORT Section the reporter is attached to : Reporter's name : Serial No. : Date when the failure occurred : Cilent's name : Hour meter : Backhoe boom No. : Length : Stamp No. : Backhoe arm No. : Length : Stamp No. + Backhoe bucket No. : Capacity : Stamp No. : Operating condi Source of information : (¢.9. From client, etc.) Defective machine description &. g. Used continuously unti | Object being dug : (e.g. Blasted and crushed sandstones were being dumped.) (expected date of repai)_ AP-8APPENDIX (LOADER) CRACK REPORT Section the reporter is attached to : Reporter's name : Serial No. : Date when the failure occurred : Hour meter : Boom stamp No. : Arm stamp No. : Loader Bucket No. : Capacity : Bucket stamp No. : Operating condition / Object being dug (¢.9. Blasted and crushed sandstones were being dumped.) ‘Source of information (.g. From client, etc.) Detective machine description AP-9APPENDIX REPAIR WELDING REPORT REPAIR WELDING REPORT Dote: 0. My. _ (Model Name. Serial No. Hour Meter: Hrs. Front type: UD _B/H Front No. & Stamp No. : Bucket Capacity: Referred DWG No./Repair Instructions No/Date : Customer Name : Dealer Name : Reporter Name/Company : ‘A. Crack condition before repair welding (A copy of the crack report is acceptable.) ‘a. Crack location (Use a UT inspection form, or visual inspection form etc.,) ». Crack location (Picture) 73) AP-10APPENDIX B.Gouged surface condition (Picture) C. After repair welding (Picture) + Welding rod used © Preheat temperature e738) AP-11APPENDIX D, Reinforcement Plate (if used, Picture) Plate material used: Plate thickness: 73) AP-12