COMPONENT CODE 08

PARTS & SERVICE REF NO. AA05057A

DATE July 18, 2011
NEWS (C)
Page 1 of 5
This Parts & Service News supersedes the previous issuance, AA5057, dated April 18, 2005. Discard AA05057.

SUBJECT: WHEEL MOTOR FRAME INSPECTIONS

PURPOSE: To inform the field of necessary wheel motor frame crack inspections.
APPLICATION: Komatsu Electric Drive Dump Trucks:
930E: 32604-32816, A30019, A30026-A30120;
930E-2: A30012, A30098, A30100, A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304 & Up;
930E-3SE: A30171, A30318, A30319 & A30322;
930E-4: A30462 & Up;
930E-4SE: A30587 & Up
FAILURE CODE: 0836HA
DESCRIPTION:

General Electric (GE) recommends that all GDY85 and GDY106 wheel motor frames be inspected for
cracks each time the wheel motor is removed for overhaul or repair.
Normal operation and loading of the wheel motor may begin to open small impurities in the wheel motor
frame casting. Small impurities are present in all castings, and may eventually lead to cracking. The most
common area for this phenomenon to occur on the wheel motor frame is at the "bell" area. Refer to Figure
1. This area is under the most stress during operation. The most susceptible areas for cracking are on the
outside surface of the bell area, in the four oclock to eight oclock region. The lesser common area is on
the inside surface of the bell area, in the ten oclock to two oclock position.
Because of differences in design, GDY85B wheels are also susceptible to cracking near the inboard hub
bearing journal. Refer to Table 1 for a list of GDY85B Komatsu part numbers.
Because of these tendencies, it is recommended that GDY85 & GDY106 wheel motor frames be
inspected for cracks in the bell area during wheel motor repair or overhaul. Because the GDY85B wheel
motor frame is more susceptible to cracks in other locations, the entire frame must be inspected. Special

AA05057A
Page 2 of 5
instructions are outlined for GDY85B wheel motor frames inspected within the United States. Refer to
US Frame Inspection Instruction For GDY85B.

FIGURE 1. CRACKING LOCATION

Frame inspection methods may vary depending on certain factors. However, some combination of mag-
netic particle inspection and/or dye penetrant must be used to inspect the frames. Each site should use the
most practical method based on capabilities and familiarity with the two inspection techniques. The fol-
lowing standards must be adhered to:
ASTM E-709 - Standard Guide for Magnetic Particle Examination
ASTM E-165 - Standard Test Method for Liquid Penetrant Examination
Any cracks that are found in the bell area can be repaired by following the process outlined in Repair
Guidelines in this bulletin. Cracks found in other areas of the frame are usually non-repairable. Contact
your Komatsu Customer Support Manager (CSM) for any questions and for further instructions.
If any cracks are found during an inspection, a frame inspection report must be sent to your Komatsu
CSM. The report must contain the frame serial number, approximate operating hours, and pictures of the
cracks showing size and location. Measuring scales to illustrate the crack and gouge size, as well as a dis-
tant picture to show crack location/orientation are highly recommended. Repairs must adhere to the
instructions documented in Repair Guidelines. The entire inspection and repair procedure must be docu-
mented in the report.
TABLE 1. GDY85B Komatsu Part Numbers

Wheel Motor Part Number Frame Part Number Misc. Part Number Frame Part Number

PB9900 GE0054 GE0527 (Conversion Kit) GE0529

PC0461 GE0054 GE0528 (Conversion Kit) GE0539

PC0667 GE0054 GE0891

PC0303 GE0429

US Frame Inspection Instructions For GDY85B

Repair shops in the US that are servicing GDY85B wheel motors are required by GE to perform an x-ray
inspection of the entire frame. The x-ray inspection will be in effect until further notice is given. This pro-

AA05057A
 Page 3 of 5
cess is being enforced in an effort to gather additional data regarding the condition of the GDY85B frame
structure population.
Shops affected by this program include: GE-Charleston Service Center, Road Machinery-Phoenix, and
GE-Tucson Service Center.
GE has identified several x-ray inspection companies to perform the required inspections. An x-ray
inspection source for the GE Charleston shop has been qualified, and the shop has been supplied with
appropriate contact information to arrange x-ray inspections.
An x-ray inspection source for Road Machinery and the GE-Tucson shops has been identified, and is cur-
rently being qualified. The GE-Tucson shop and the Road Machinery shop will be required to have all
GDY85B frame structures x-ray inspected effective immediately after qualification of an x-ray inspection
source. GE will contact Road Machinery and the GE-Tucson shop with appropriate x-ray inspection
source contact information upon completion of source qualification.
GE will receive and evaluate all x-ray results, disposition the frames for scrap or reuse, and communicate
the findings to the appropriate shops and to Komastu.
GE will cover all reasonable costs associated with x-ray inspection of the GDY85B frame structures.
REPAIR GUIDELINES

Joint Preparation

When a repairable crack is found near the bell area, the following guidelines are to be used:

1. Cracks smaller than 1 in. (25.4 mm) in length with a depth of 0.25 in. (6.4 mm) or less can be
removed without arc gouging. Remove the cracks with a die grinder and burr. Blend the area with
an angle grinder, and treat it with a mounted stone. Finish the area with a 60 grit flapper wheel.
Ensure the repair area is blended with the adjacent surface.
2. Cracks deeper than 0.120 in. (3.1 mm) must be welded. An alternative weld repair option for
small cracks such as this would be to use 3/32 in. or 1/8 in. 9018 low hydrogen electrodes.
3. All cracks smaller than 3 in. (76.2 mm) with a depth greater than 0.25 in. (6.4 mm) must be
removed via arc gouging and weld repaired. Gouges must be at least 3 in. (76.2 mm) long. It is not
acceptable for a gouge to be less than 3 in. (76.2 mm).
The frame must be preheated to 350 50 F (177 28 C) before gouging. Whenever possible,
use an oven to preheat the frame to ensure temperature uniformity. If an oven is not available, the
temperature must be checked around the entire perimeter of the crack at a distance of 4 in. (102
mm).
4. The maximum repairable crack dimension (including crack removal and cleaning) is 15 in. (38.1
cm) for cracks in Zone A (Figure 2). Maximum repairable crack dimension for cracks in Zone B
is 10 in. (25.4 cm). Exceeding these maximums may cause deformation of the frame.
5. Air arc gouging is the only acceptable method of gouging to be used.
6. Gouge depth will determine the width and span of the opening. Allow access of the Metal Inert
Gas (MIG) gun to within 0.5 in. (13 mm) of the root of the gouged area. Feather out to each side
of the crack. Remove any slag and foreign debris left behind after gouging. If the crack originally
extended all the way through the section, a "V" weld preparation is recommended if access to the
back side is attainable.
7. Sand pockets and inclusions that are found in and around the crack location must be removed
completely.

AA05057A
Page 4 of 5
8. After extensive repairs, the frame must be checked for misalignment or extensive runout in the
flange fits and in the bearing fits.

FIGURE 2. CRACK LOCATION ZONES

Welder Qualifications

Welders performing these repairs must meet the standards of the American Welding Society or the equiv-
alent.

Equipment
Air arc gouging equipment
Die grinder/angle grinder
Non-destructive test equipment (MPI, dye penetrant)
MIG welding equipment (0.045 in. - 70, S-6 solid core wire)
Shielding gas: 90/10 Ar CO2 (90% Argon, 10% CO2)

Welding Procedure

1. Preheat the frame to 350 50 F (177 28 C). Whenever possible, use an oven to preheat the
frame to ensure temperature uniformity. If an oven is not available, the temperature must be
checked around the entire perimeter of the crack at a distance of 4 in. (102 mm). The temperature
inside this area must not drop below 300 F (149 C) during the entire welding process.
2. Use 0.045 in. -70, S-6 filler wire and 90/10 Ar CO2 shielding gas with a spray transfer convex
stringer bead process. Stringers running longitudinally through the filler area must not exceed 0.5
in. (13 mm). Stringer bead passes though the fill zone must alternate direction to minimize stress
input.
3. Peen weld after each pass.
4. If the crack extended through the thickness of the frame radius, but the location did not allow for
a "V" preparation, a backing plate must be used to ensure weld continuity, throughout. Remove
the backing plate after welding and back gouge any possible undercut or impurities. Refill and
smooth to the original radius.

AA05057A
 Page 5 of 5
5. Once the weld fill is complete, grind and smooth to the original radius.

Post Weld

Post-heat the weld area to 350 50 F (177 28 C) for one hour and monitor. After an hour, allow the
frame to cool in an area with a minimum ambient temperature of 60 F (16 C). Allow the frame to sit
until the weld area cools to at least 100 F (38 C).

Weld Inspection - Acceptance

Use MPI or dye penetrant to inspect the weld, 3 in. (76 mm) out around the perimeter of the weld. Weld
repairs are acceptable if no indications are found. If indications are found in the weld vicinity, contact
your Komatsu CSM for more information on how to proceed.

AA05057A