Overflow Guard Installation Procedure for Certain Buckets on R1600G and R1600H Load Haul Dump Machines{7186, 7186} Caterpillar

Load Haul Dump:

R1600 (S/N: 9XP1-UP; 9EW1-UP)

R1600G (S/N: 9PP1-UP; 9YZ1-UP)

R1600H (S/N: 9SD1-UP)

Introduction

This special instruction covers the installation procedure for the bucket overflow guard on 227-4703 Bucket and 203-1792 Bucket . This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

ReferenceDisassembly and Assembly, KENR6271, "Steering Frame Lock - Remove and Install".

ReferenceService Manual, RENR8594, "Machining and Welding Information for Load Haul Dumps".

Safety Section

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Procedure for the 227-4703 Bucket

1. Move the machine to a hard, level surface, that is away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Lower the bucket to the ground and apply a slight downward pressure.

4. Stop the engine.

5. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

6. Turn the disconnect switch to the OFF position.

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Illustration 1	g02322973
(2) Bucket leveling gauge

7. Remove and discard material (1) as highlighted in Illustration 1.

8. Remove bucket leveling gauge (2). Retain for installation purposes.

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Illustration 2	g02323053
(A) 300 mm (11.8 inch) (B) 50 mm (1.96 inch) (W1) 12 mm (0.47 inch)

9. Position bucket leveling gauge (2) removed in Step 8 to the bucket.

   Note: Use the existing bucket leveling gauge location for reference.

10. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

11. Weld bucket leveling gauge (2) to the bucket.

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Illustration 3	g02323033
(3) 266-0381 Bar - Spill Guard (4) 266-0382 Plates (5) 266-0385 Shroud - Spill Guard (C) 249 mm (9.80 inch) (D) 77 mm (3.03 inch) (W2) 12 mm (0.47 inch)

12. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

13. Position and tack weld 266-0381 Bar - Spill Guard (3) and 266-0385 Shroud - Spill Guard (5) to the bucket.

14. Position and tack weld two 266-0382 Plates (4) to the bucket.

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Illustration 4	g02323073
(3) 266-0381 Bar - Spill Guard (4) 266-0382 Plates (5) 266-0385 Shroud - Spill Guard (W3) 12 mm (0.47 inch) (W4) 12 mm (0.47 inch) (W5) 16 mm (0.63 inch)

15. Weld 266-0381 Bar - Spill Guard (3), 266-0385 Shroud - Spill Guard (5), and two 266-0382 Plates (4) to the bucket.

Procedure for the 203-1792 Bucket

1. Move the machine to a hard, level surface, that is away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Lower the bucket to the ground and apply a slight downward pressure.

4. Stop the engine.

5. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

6. Turn the disconnect switch to the OFF position.

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Illustration 5	g02322973
(2) Bucket leveling gauge

7. Remove and discard material (1) as highlighted.

8. Remove bucket leveling gauge (2) and retain for installation purposes.

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Illustration 6	g02323053
(A) 300 mm (11.8 inch) (B) 50 mm (1.96 inch) (W1) 12 mm (0.47 inch)

9. Position bucket leveling gauge (2) removed in Step 8 to the bucket.

   Note: Use the existing bucket leveling gauge location for reference.

10. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

11. Weld bucket leveling gauge (2) to the bucket.

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Illustration 7	g02323093
(3) 266-0381 Bar - Spill Guard (4) 266-0382 Plates (5) 266-0383 Shroud - Spill Guard (C) 99 mm (3.90 inch) (D) 77 mm (3.03 inch) (W2) 12 mm (0.47 inch)

12. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

13. Position and tack weld 266-0381 Bar - Spill Guard (3) and 266-0383 Shroud - Spill Guard (5) to the bucket.

14. Position and tack weld two 266-0382 Plates (4) to the bucket.

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Illustration 8	g02323073
(3) 266-0381 Bar - Spill Guard (4) 266-0382 Plates (5) 266-0383 Shroud - Spill Guard (W3) 12 mm (0.47 inch) (W4) 12 mm (0.47 inch) (W5) 16 mm (0.63 inch)

15. Weld 266-0381 Bar - Spill Guard (3), 266-0383 Shroud - Spill Guard (5), and two 266-0382 Plates (4) to the bucket.