COMPONENT CODE: 71

NO.: AH08507a
PARTS & SERVICE NEWS DATE: October 11, 2013
Page 1 of 11
SUBJECT: Steel structure

PURPOSE: Repair welding procedure / Revision

APPLICATION: PC3000-6; PC4000-6; PC5500-6; PC8000-6

FAILURE CODE: 7100FE

DESCRIPTION:

:
• Before carrying out any repairs, read all the safety instructions
of the Operation and Maintenance manual of your shovel.
• The local safety rules must also be observed.

Content
1. Introduction
2. General Protective Measures
3. Steps of the weld repair procedure
4. Selection of appropriate electrodes, filler materials and shielding gas
4.1 Selection of appropriate electrodes
4.2 Selection of appropriate filler materials
5. Preparation of the defective Part
6. Working temperature range
7. Carrying out the Weld Repair
8. Post heating
9. Inspection of Repair

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1. Introduction

Weld repairs can cause severe damage to an entire structure if performed incorrectly.
Therefore we recommend consulting your Komatsu Service Organization in order to
avoid improper welding procedures. If cracks are found in the steel construction of your
excavator, please inform our service department as soon as possible. Attach suitable
information material (photos, catalogue drawings etc.) showing the location and nature
of the crack.

2. General Protective Measures

Welding operations can cause damage to electronic components (Computers, Control

Units, Sensors etc.) in case the welding current goes through these units. Therefore
protective measures are necessary before any weld repair is started.
1. Observe the prevailing safety and fire prevention regulations. Get advice from
authorized Electricians for all medium and high voltage systems related
questions.
2. Before any weld repair is started, a survey should be made of the area and all
safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil
lines, electrical cables and synthetic materials.
3. Remove the battery main switch keys and switch off all circuit breakers, refer to
the Operation Manual of the Excavator for more information.
4. Attach the welding ground directly to the part that is being repaired. Do not allow
welding current to go through bearings. Welding current could arc the bearings,
resulting in severe damage to the bearing.

3. Steps of the weld repair procedure

1. Clean the damaged part or area to be repaired.

2. Inspect the worn or fractured area by visual inspection and/or non-destructive
testing.
3. Determine the type of material to be repaired.
4. Determine the welding electrode or the welding wire and process to be used.
5. Preheat before welding.
6. Weld by using appropriate welding techniques.
7. Post heat.
8. Grind the weld if necessary
9. Make a survey of the repair welding.

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4. Selection of appropriate welding electrodes, filler materials and

shielding gas
Table 1: Materials to be welded
Material
designation Material

a S235JR /1.0038
b S355J2+N / P355NL1 / 1.0570 / 1.0566
c P460N / 1.8905
d S690Q/QL / 1.8931 / 1.8928
e HB400
f G24Mn6V / 1.1118
g G18NiMoCr36 / 1.6759
h G42CrMo4V / 1.7225
i 30CrNiMo8 / 1.6580
k ESCO cast iron (adapter and lips); Hensley cast iron

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4.1 Selection of appropriate welding electrodes

Table 2: The following welding electrodes are required for the weld repairs:

Welding Electrode
Key (Shielded Metal Arc Welding)
Comment
number
AWS/ASME DIN EN ISO 2560-A
Fine grained steel
4 E 7016-H8 E 38 2 B 12 H10
to S(P)355
5 E 7018-G H4 E 46 6 1Ni B 4 2 H5 to S(P)460
Fine grained steel
7 E 8018-G H4 E 50 6 Mn1Ni B 4 2 H5
to S(P)500
9 E 10018-G H4 E 69 MN2NiCrMo B 4 2 H5* S690QL1
*DIN EN 757

Table 3: Types of welding electrodes to be used for the different materials

Material a b c d e f g h i k
a 4
b 4 4
c 4 4 5
d 4 4 5 9 9
e 4 7 7 7 7 9
f 4 4 4 4 4
g 4 4 5 9 5 9 7
h 4 4 5 7 5 7 7
i 4 4 5 9 5 9 7 9
k 9 9

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4.2. Selection of appropriate filler materials

Table 4: The following filler materials are required for the weld repairs

Filler Material
Key (Gas shielded Metal Arc Welding) Comment
number
AWS/ASME DIN EN ISO 2560-A
Only Tack welding
20 ER 80S-G Solid wire electrode
without preheating
Solid wire electrode
21 ER 70S-6 to S(P)460
G 46 4 M G4Si1
Solid wire electrode*
25 ER 100S-G S690QL1
GZ Mn3Ni1Mo
Solid wire electrode* S690QL1
25a ER 90S-G
G 62 4 M MN3NiMo Heat-treatable steel
*DIN EN ISO 16834-A

Table 5: Types of filler materials to be used for the different materials

Material a b c d e f g h i k
a 21
b 21 21
c 21 21 21
d 21 21 21 25/25a 25/25a
e 25/25a 25/25a 25/25a 25/25a 25/25a 25/25a
f 21 21 21 21 21
g 21 21 25/25a 25/25a 21 25/25a 25/25a
h 21 21 21 25/25a 21 25/25a 25/25a
i 21 21 21 25/25a 21 25/25a 25/25a 25/25a
k 25/25a 25/25a


• We recommend using Shielding Gas according
DIN EN ISO 14175:
- M21 (15 to 25 % CO2 plus 85 to 75 % Ar) or
- 100 % CO2.

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5. Preparation of the defective Part

• Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust,
spalled material or any other materials, which may be detrimental to a weld.
• Inspect the fractured areas carefully by non-destructive testing such as
magnetic particle or dye penetrant inspection.
• When removing cracks, a V groove should be made with a 30° to 45° angle.
Remove defective material up to the bottom of the crack.

Illustration 1

Use electrodes out of a freshly opened can or from an electrode holding oven. Dry
the electrodes according to the instructions of the electrode manufacturer.
Preheating of the part before preparing it for weld repair is essential to reduce the
thermal shock. The preheat temperature depends on the composition of the
material, see table 7 for the required temperature. Measure the temperature
beside the joint at a distance equal to the sheet metal thickness using suitable
temperature indicating devices.

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6. Working temperature range

Table 7
Groove Preheat Interpass Post heat
Material depth temperature temperature temperature
(mm) (°C) (°C) (drop per hour)
-10 20
S355 (X60) 10 - 20 50
S460 220
>20 - 50 100
1)
>50 150
S690 -10 50 150
>10 - 20 100 180
>20 150 220
-40 20
HB 400 >40 - 70 75
(Dillidur; XAR, 220
>70 - 100 100
Hardox)
>100 150
-20 50 180
>20 - 30 100
HB 500 50 degree. max.
(Dillidur; XAR, >30 - 40 125
Hardox) 220
>40 - 60 150
>60 175

GS24Mn6 <10 50 150

GS18NiMoCr36 <10 - 20 100
2) 180
>20 150
<10 50 150
GS22NiMoCr56 <10 - 20 100
180
>20 150
ESCO cast iron
150 230
Hensley cast iron
42CrMo4 320 350
30CrNiMo8 280 320

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7. Carrying out the Weld Repair


• All weld repairs should be carried out by qualified and
experienced welders.
• Provide the necessary equipment such as the correct clothing,
head gear, exhausts systems or respirators and if required
platforms for safe access to the repair area.

• It is important to maintain the preheat temperature according to table 7

throughout the repair.
• The interpass temperature should never exceed the maximum permissible
value shown in table 7. Measure the temperature beside the joint at a distance
equal to the sheet metal thickness using suitable temperature indicating
devices.
• All cracks through the parent material will require a welding from both sides,
see illustration 1. The Service Bulletin No. 21-594 contains instructions for
making a “Man Hole” which is necessary for weld repairs from inside the boom
or stick.
• When welding in a vertical position always weld using the vertical up technique.
Properly applied multiple pass welding is the required procedure, illustration 2.
• Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove
wall before welding the space between the beads (A and B). Repeat the
calking of beads (A and B) at each weld layer.

Illustration 2

• Once a repair has been started by preheating and welding, the part should be
worked on until completed.
• A recommended technique for repair is to butter the groove with weld metal.
Buttering is the addition of one or more layers of weld metal to the face of the
joint or surfaces to be welded.

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• After the welding has been completed, check the repair for any undercuts,
overlaps or any other notch type discontinuity while the preheat is still up to
temperature. Make any repair necessary at this time.
• After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit
grinding material. All grinding marks should be parallel to the direction of
primary stress if possible. Make sure there is a smooth transition between the
weld metal and the parent plate.

8. Post heating
• Maintain the preheat temperature according to table 7 for at least 15 minutes
after the weld repair is finished and then cool the repair area slowly, refer to
table 7 for maximum allowable temperature drop per hour.

9. Inspection of Repair
• Inspect the completed weld after it has cooled to the ambient temperature by
non-destructive procedures as dye penetrant, or magnetic particle inspection
and ultrasonic inspection, if possible.
• A final inspection of the weld repair should be made after 24 hours in order to
detect hydrogen induced cracks.
• If surface defects are found, remove all defects by grinding to a maximum
depth of 1.5 mm. Larger defects have to be removed according to the repair
procedures described on the preceding pages. Grind welds so they blend in
with the parent material. All spot welding also require preheating and post
heating.

 • It is not recommended to weld on reinforcement plates as the

main stress will remain ~float~ through the steel structure
regardless how many additional plates would be applied to the
structure.

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Illustration 3

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Illustration 4

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