Komatsu Welding Shop Manual I & II - SEBF14001

Welding is a technique used widely in many industries and it is common knowledge that welding is used to connect metals. Many welding techniques are used in the manufacture and maintenance of construct1on machinery. Welding is often used to built up the structure of construction machinery and its important parts and thus the quality of the weld will greatly affect the overall quality of the machinery. This means that welding techniques play an essential role in the service department. This manual will describe how to do welding work properly


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBF14001
Total Pages : 635

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TABLE OF CONTENTS :

GENERAL INSTRUCTIONS
APPLIED INSTRUCTIONS
11 BASIC WELDING
12 HARD-FACING OF WEAR PARTS
13 REPAIR OF RADIATOR AND OIL COOLER
20 REPAIR OF BULLDOZERS AND DOZER SHOVELS BY WELDING
30 REPAIR OF DUMP TRUCKS BY WELDING
40 REPAIR OF HYDRAULIC EXCAVATORS BY WELDING
50 REPAIR OF WHEEL LOADERS BY WELDING
60 REPAIR OF MOTOR GRADERS BY WELDING
70 REPAIR OF MOTOR SCRAPER BY WELDING
80 REPAIR OF SOIL COMPACTOR BY WELDING
LIST OF SERVICE NEWS NO RELATED TO WELDING

WELDING I
CONTENTS
GENERAL INSTRUCTIONS
General description of welding techniques
Features of welding methods
Selecting welding methods
Preparation for welding
Welding techniques
Weld defects and countermeasures
How to distinguish materials and how to check welded areas
How to read welding symbols
How to handle gas (oxyacetylene) welders and cutters
Preventing accidents
Cost of welding consumables
Examples of troubles in welded structures and countermeasures
List of standards of welding rods by countries
List of standards of metal materials by countries
Melting temperatures of various base metals and alloys
Conversion table
Names of standards in various countries
A guide to welding terms
BASIC WELDING
Items required for welding repairs
Procedure for checking for cracks
Preparation of edges by gouging
Welding procedure
Finishing procedure with a grinder
Peening procedure
Weldability of steel materials
Sections to be repaired by welding and selection of welding rods
List of major materials of bulldozers
Points for ensuring quality after welding
HARD-FACING OF WEAR PARTS
Hard facing
Types of metal wear
Build up welding procedure
General precautions for build up welding
Examples of hard facing
REPAIR OF RADIATOR AND OIL COOLER
Procedure for repairing leakage of water from radiator core
Applicable range
Action to take when water starts leaking
Confirming location of water leakage
Factors causing water leakage
Removal
Disassembly
Repair tools and equipment
Repair procedure
Checking results
Assembly of core assembly
Pressurinzing check
Reassembly
REPAIR OF BULLDOZERS AND DOZER SHOVELS BY WELDING
MAIN FRAME(Example of D455A)
TRACK FRAME(Example of D455A)
BLADE
Type and uses of blades
Preventing wear of blades
Scheduled repair of blades
Repair and rebuilding of blades
BUCKET
Types and uses of buckets
Repair and rebuilding of buckets
Replacing a bucket edge
RIPPER ADAPTER SHANK
REPAIR OF DUMP TRUCKS BY WELDING
MAIN FRAME(Example of HD320-2 and HD325-2)

WELDING II
CONTENTS
SAFETY IN OPERATIONS
Safety in operations
WELDING EQUIPMENT AND BASIC WELDING TECHNICS
Purchassing priorities
Welding equipment groups
Arg air gouging
Vertical welding rod and uranami welding electrode
Comparison of CO2 semi-automatic welding and manual welding
Equipment part numbers
Gas cutting
Flat welding
Vertical welding
Procedure for checking for cracks
Welding procedure
Gas cutting work
CO2 gas shielded semi-automatic arc welding
Penetration welding
Finishing procedure with a grinder
WELDING DEFECTS
Defectives shape of bead
Lack of penetration
Welding blow through
Standard edge preparation
Strength of butt welding
Cracks
WELDING REPAIR
Basic flowchart for welding cracks
General precautions for welding repair work(summary)
Check points for welding repair
Selection of welding rods
Preheating,postheating
List of materials
Welding repair method for different structures
Reinforcement plate
Gouging
Method of inserting back plate in box frame
Results of bending fatigue test on box frame
Way of bending or setting reinforcement plate
Track welding
COLLECTION OF EXAMPLES
Bulldozers
Hydraulic excavators(Backhoe specification)
Hydraulic excavators(Loading shovel specification)
Dump trucks
Wheel loadors
Motor graders
Bulldozers
Hydraulic excavators(Loading shovel specification)
Dump trucks
Wheel loaders
Motor graders
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