TECHNICAL REPORT

From: Kris Burford

To: Mick Matsumoto
Subject: WA1200-3 50006 Front frame crack repair
Date: 11/08/2005
Copy: Luke Muras; Chris Daly

Summary
th
Friday the 29 of July Komatsu/ Bulga coal staff attempted to preform a right hand steering
cylinder change out on the WA1200-3. Upon removal the front frame pin (42C-46-12430) was
gauged out from the top & bottom in preparation for removal.

A hydraulic jack was placed beneath the pin under the front frame of the machine. Pushing
upward on the pin the top plate attached to the front frame broke away from the frame whilst
retaining the pin.

Preparation was then made for the immediate repair of the front frame due to availability. A
private contractor was used to make the repairs to enable the machine to return to work.

Results

Pin Removal-

Before the front steering cylinder pin was removed it was noticed that the keeper
plate (42C-46-12461) & taper/ spacer (42C-46-12440) was missing from the bottom of the
cylinder pin. This inturn would allow considerable movement of the pin & put stress on the top
retainer of the pin.

Re- secured

TECHNICAL REPORT WA1200-3 BULGA Page 1 of 6 12/08/2005

 Bottom of cylinder pin.
Pin gouged, retainer plate
missing.

Figure 01

Cable tray installed- Harness

flex replaced with rhino flex.

42C-46-12440 Spacer

42C-46-12461 Plate

Cracked plate

Figure 02
Weight on pin from
hydraulic jack

TECHNICAL REPORT WA1200-3 BULGA Page 2 of 6 12/08/2005

Repair-

All hydraulic lines affecting access to the damaged area were removed before repairs could start
on the broken area. The broken piece of plate was removed from the machine complete with the
pin. The pin was removed with a hydraulic press leaving the broken plate & boss in tacked.

Plate
Boss

Steering cylinder

Gen-set main
R/H deck & se
Figure 03 other enclosu

Laying the plate & boss back into place on the machine a spacer was fabricated using
measurements from the opposite side.

Fabricated
Spacer

Figure 04

Red line is cracked area in

need of repair

Figure 05

TECHNICAL REPORT WA1200-3 BULGA Page 3 of 6 12/08/2005

Once in place the cracked area was back gouged. “V” prep was used, approximately 32mm in
width & at a 40 degree angle through the depth of the plate. Cracks to the side of the detached
piece of plate were also gouged in preparation for repair.

To remove carbon from the gouged area a grinder was used to ensure the prepped area was
ready for welding.

The plate was then pre-heated to 80 degrees. An oxy torched was used to achieve heat into the
area; monitored with a calibrated heat gun.

The type of wire used for the weld was 3XP 1.2 wire

40 degree angle

Figure 06

A “string of beads” method was used to weld the area back together rather than a weave weld.
This process took some time due to the amount of weld in the area.

Pre-heated 80 degree

Beads of weld

(Drawing not
accurate-
example only) Figure 07

The repair was made with the new cylinder pin () in place, eliminating the need for line boring.
Once complete the pin was checked for clearance. The weld was then cleaned & finished for
cylinder re- installation.

A small crack was also repaired using the same

method on the bottom cylinder retaining plate as
movement & fatigue had caused cracking also.

Small repair on
bottom retainer
plate

Figure 08

TECHNICAL REPORT WA1200-3 BULGA Page 4 of 6 12/08/2005

Cylinder installation-

The steering cylinder was then re-installed using new-

Pin (42C-46-12430)
Bush (42C-46-12420)
Bush (42C-46-12451)
Spacer (42C-46-12440)
Plate (42C-46-12461)

The installation was carried out as per the service manual with all tolerances with in specification.

Figure 09

TECHNICAL REPORT WA1200-3 BULGA Page 5 of 6 12/08/2005

 Conclusions

It is conclusive that the crack that had formed in the steering cylinder pin upper mounting plate
was caused by the stress on the plate (42C-46-12461) due to the spacer (42C-46-12440) &
retainer plate missing during operation of the machine.

It seems the fatigue in this area was enough to cause the plate to dislodge from the main
structure as shown in figure 02.

Cracked area

Movement of pin at
Figure 10
base due to tapered
spacer & retainer plate
missing

With the above mentioned repairs carried out & the relevant parts replaced to specification it
seems unlikely that this area of the machine will pose an ongoing issue.

TECHNICAL REPORT WA1200-3 BULGA Page 6 of 6 12/08/2005