Guide for the repairs excavator

structures by welding

Print no. 604.07.189.01 - English

 FORWARD

If construction machineries work under severe conditions for long period, welded structural components may
crack.

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, 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 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), FIAT KOBELCO sales support servicemen and FIAT KOBELCO 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 FIAT KOBELCO 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.
 TABLE OF CONTENTS

TITLE PAGE

Foreword

Safety rules 3

Don't's: fundamentals 8

Inspection procedure 13

Repair procedures 14
- Table no. 1 - Dipper stick - Series FH 15
- Table no. 2 - Dipper stick - Series EX
Models EX135 - EX165 - EX215 19
- Table no. 3 - Dipper stick - Series EX
Models EX235 - EX255 - EX285 - EX355 - EX455 25
- Table no. 4 - Monobloc boom 31
- Table no. 5 - Triple articulation - Arm no. 1 51
- Table no. 6 - Upperstructure 55
- Table no. 7 - Undercarriage 67

1
2
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Safety first.
• Allow only trained, qualified, authorized personnel to
perform repair welding.
(American Welding Society Class 3 or up, or equiv-
alent)
• Carefully read and follow the instructions in this
manual. Also, read the safety section of the opera-
tor's manual before performing any welding work.
• Be sure to follow your local safety regulations.

SAFETY PRECAUTIONS FOR REPAIR

WELDING WORK

• Prepare for emergencies.

• Be prepared if a fire starts or if an accident occurs.
• Wear protective clothing.
• Wear close fitting clothing and safety equipment
appropriate for the job.
• Do not wear a necktie, scarf, loose clothing, or
necklace when you work near machine tools or
moving parts. If these items get caught in the ma-
chine, severe injury could result.
• Remove rings and other jewelry, to help avoid elec-
tric shock and entanglement in moving parts.
• Be sure that clothing and gloves are dry, not damp.
• Use tools and equipments appropriate for the work to
be 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 elec-tric
shock prevention device.
• Protect against hazardous light rays and hot metal
splatters.
• Hazardous light rays and hot metal splatters are
produced when arc-welding. 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 eyes and face.
• Protect against noise.
Prolonged exposure to loud noise can cause impair-
ment or loss of hearing.

3
 SAFETY
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against constant or
uncomfortably loud noises.
• Protect against flying debris.
• Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.

PRECAUTIONS FOR WELDING AND

HEATING

• Harzardous fumes can be generated when paint is

heated by welding, soldering, or using a torch.
Do all such work outside or in a well-ventilated area.
• Avoid potentially toxic fumes and dust.
• Remove paint before welding or heating.
• If you sana or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper
with soap and water before welding. 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 hoses can be accidentally cut if splat-
ters fall on them. Remove hoses from splatter area
if possible, or install temporary fire resistant guards
to protect hoses.
• 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, provide temporary
fire resistant guards over them.

4
 SAFETY
CAUTIONS TO BE TAKEN WHILE WELD-
ING AND HEATING

• Avoid welding or heating using a torch on or around

hydraulic components or lines.
• After welding or heating work is complete, always
check for smoke or for any other indication of fire.

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When getting on and off the machine, always main-
tain a three-point contact with the steps and han-
drails, and face the machine.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when getting on or off the
machine.

PRECAUTIONS FOR MACHINE OPERA-

TION

• 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 unat-
tended.
• Take precautions when operating the machine.
• Be sure to start the engine only while 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.
• Machines experiencing trouble may move in unex-
pected 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.

5
 SAFETY
• Learn the meaning of all flags, signs, and mark-
ings 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.
• Keep riders off the machine. Only allow the opera-
tor on the machine.

PRACTICE SAFE REPAIR WELDING

• Fully understand repair welding procedures to be

done before doing work. Also, make sure that your
co-workers 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 raised
by its arm and boom.
• 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.
• 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.

6
 SAFETY
• Illuminate work area safely.
• Illuminate your work area adequately but safely.
• Use a portable safely light for working inside or
under the 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 weld-
ing on the machine.

7
 DON'T'S: FUNDAMENTALS
PREPARATIONS

• DO NOT perform gouging work without con- • DO NOT let anyone without a proper welding
firming the number, size, and location of cracks/ certificate (American Welding Society Class 3 or
flaws. up, or equivalent) perform repair welding work.

Without knowing the cracks/flaws to be removed, If an unqualified person performs welding work,
places with no cracks/flaws detected may be re- incomplete fusion or poor penetration which causes
moved and/or sufficient gouging depth may not be decrease in strength may result.
obtained in order to remove cracks/flaws.

• DO NOT perform repair welding work in rain or

• DO NOT perform repair welding work without falling snow.
recording all confirmed data.
Electrocution may result. Also, blowholes or cracks
Without having records of previous repair work, any may result.
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 • DO NOT perform repair welding on surfaces to
previously repaired place, the cause of the crack which lubricants, mud, and/or paint are at-
may not be found. tached.

A fire may result. Also, blowholes may be induced.

• DO NOT perform repair welding without thor- Moreover, when removing cracks by gouging, the
oughly understanding the contents of corrective cracks may not be completely removed as the
and/or preventive measure drawings. depths and directions of cracks may not be correctly
located.
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 thor-

oughly understanding corrective and/or preven-
tive measure procedure (steps).

If correct steps are not followed, repairs for box type

structure, i.e. inner side welding, rib welding and/or
crack removing, may be incompletely performed or
completely hindered from being performed.

8
 DON'T'S: FUNDAMENTALS
RESTRAINING
• DO NOT perform work without setting restraint
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 dis-
torted.
Weak restraint fixtures may distort and thus may not
function as proper restraint fixtures.
• DO NOT weld a restraint fixtures 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 to a part having
a match without confirming the dimensions of
the matching parte.
If welding is performed without first measuring the
dimensions of the matching parts, the match may
not fit; welding-induced distortion cannot be cor-
rected without knowing the original dimensions.
• DO NOT preheat welding material before setting
required restraint fixtures.
Similar to the case of welding work, as the tempera-
ture 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 tem-
perature 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 spe-
cial 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.
9
 DON'T'S: FUNDAMENTALS
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.
• 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 finish a gouging-
performed part with grinding before starting to weld
on it.
• DO NOT use flux cored wire or coated electrode
which is not dry.

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.
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.

Electrocution or burns may result. Also, appropriate • DO NOT use any electrodes or welding wires
heating or welding cannot be done with it. except for those specified.

Desired strength may not be obtained. Also, inappro-

• DO NOT perform gouging using a gas burner on priate bead forms may result, causing cracks.
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 confirm-
ing the thickness of plate first.
When the back side cannot be welded and if the plate
is penetrated accidentally, uncorrectable notches
will remain.
• DO NOT generate arc strikes (sparks) on places
other than the welding part.
• DO NOT leave any failures uncorrected.
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 tem-
perature and lower than 400 °C (752 °F).

Arc strike parts harden. Even after grind finishing,

cracks may appear at the bent areas of plates or
rounded areas.

10
 DON'T'S: FUNDAMENTALS
• 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.
• DO NOT perform welding work without tak-ing
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 symmetri-
cal welding.
If the work is done unevenly, excessive distortion
will result.
• DO NOT weld gas cut surfaces without grind
finishing them first.
Poor penetration caused by notches on cut surface
will result. Also, weld defect caused by slag inclu-
sion 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, caus-ing
straightening to become very difficult.
• DO NOT heat high tensile strength steel or spe-
cial 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.
• DO NOT perform straightening on one side only.
Amount of distortion increases and distortion direc-
tions may become multi-dimensional.
• DO NOT heat and then rapidly cool machined
surfaces.
Distortion will develop on machined surfaces.
11
 DON'T'S: FUNDAMENTALS
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.
12
FINISHING
• DO NOT leave finished surfaces coarser than
specified.
Stress concentration may result if finished surface
is left coarse or notch(es) exist.
• 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.
 INSPECTION PROCEDURE
INSPECT MACHINE BEFORE REPAIRING

Arm cylinder

ä
Arm
Boom
ä

ä
Bucket cylider ä

Link ä
ä Boom cylinder ä
Link

ä
Bucket
ä

Tooth

ä
Track Frame

Track Link

}
ä
Track
ä
Track Shoe

For other inspection and maintenance procedures, refer to the Operator Manual.

1. Cleaning before the visual check 2. Visual check

Thoroughly remove any grease and dust from the Check for any cracks in the welded portions of the
surface of the structure before performing the visual structure.
check.

If a crack is found, indicate the crack position and

inform the workshop. Illustrate the crack position and
lenght as accurately as possible on the main drawing
of the part and dispatch the information to
FIAT KOBELCO Call Centre.

13
 REPAIR PROCEDURES

14
 TABLE No. 1

Excavators

Series FH, all models

See page 17

Dipper stick

15
16
 TABLE No. 2

Excavators

Series EX

Models: EX135 - EX165 - EX215

ä

See page 21

See page 23

Dipper stick

19
20
 TABLE No. 3

Excavators

Series EX *

Models: EX235 - EX255 - EX285 - EX355 - EX455

See page 27

See page 29

Dipper stick

* On series FH the repair solution is similar

25
 REPAIR PROCEDURE

1.1 Scarf both side weldings, as indicated in Fig. 1 and detail a.

1.2 Cut on the same dimensions the lower cover and remove it. Fig. 2 provides an assembly view
of the item, consult it when performing the operations here below.

1.3 Grind all scarfed zones, chamfering them as indicated in sections "A", "B", "C", "D", "E", "F",
"G", "H".

2.1 Repair the crack on the plate, as indicated in section "J-J".

1st phase: Scarf the inner side of the entire crack; check with penetrating liquid. If cracks are
still seen, repeat the operation;
2nd phase: Weld and grind flat, without leaving indentations;
3rd phase: Scarf the outer side, making sure that you reach the welding inside. Check with
penetrating liquid and repeat the steps mentioned above;
4th phase: Weld and grind flat, without indentations.

2.2 Attach the welding support strap (prepared in accordance with the enclosed sketch) as indi-
cated in Fig. 2 Sections "A" and "B" and in Fig. 3.

3.1 Spot weld the straps, as indicated in Fig. 3.

3.2 Install the cover, as indicated in Fig. 3 and section "K-K".

3.3 In the zone without support, if possible, place 2 copper supports or two thin steel plates.

3.4 Weld and grind flat, without indentations, the 2 joints, as indicated in section "K-K" welded. If the
thin plates have been used as support, grind them away completely.

3.5 Weld the sides, as indicated in section "H" welded.

Note No welding faults are allowed.

All faults must be repaired.

Note: Use AWS E 7016 or 7018 electrodes.

26
 TAVOLA N. 4

Excavators

Series FH - Series EX

All models

Lower side see pages

45, 47 and 49

Upper see page 35

Lower see page 43

ä
ä

ä
ä

See page 37 ä

See page 39 See page 41

See page 33

Monobloc boom

31
32
 TABLE No. 5

Excavators

Series FH - Series EX

All models

See page 53

ä
ä

See page 53

Triple articulation - Arm no. 1

51
52
 TABLE No. 6

Excavators

Series FH - Series EX

All models

See page 59

See page 63
See page 61
ä

See page 65
ä

ä
ä

See page 57
ä

Upperstructure

55
56
 TABLE No. 7

Excavators

Series FH - Series EX

All models

See page 67

Undercarriage

67
68
FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Strada Settimo 323, Settimo Torinese (TO) - Italy

Print no. 604.07.189.01 - Edition August 2002