Procedure to Install Weld-On Ground Engagement Tool (GET) Segments to 442-4005 Bucket Gp {6101, 6818} Caterpillar

Load Haul Dump:

R1700G (S/N: SBR1-UP)

Work Tool:

BUCKET (S/N: ARN1-UP; 7NW1-UP)

Introduction

This special instruction covers the procedure to install weld-on GET segments to the 442-4005 Bucket Gp . Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

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.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering.

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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 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

ReferenceDisassembly and Assembly, KENR6271, "R1700G Load Haul Dump Machine Systems"

Required Parts

Welding Requirements

For welds applied using Gas Metal Arc Welding (GMAW) to install the GET segments use AWS A5.1 E7018 or AWS A5.20 E71T-1 wire with a diameter of 1.6 mm (0.063 inch). A gas mixture of 75 percent argon and 25 percent carbon dioxide is recommended.

For welds applied using Manual Metal Arc Welding (MMAW) to install the GET segments used AWS E7018 electrodes.

Bucket Preparation

1. Remove the bucket from the machine. Refer to Disassembly and Assembly, "Bucket - Remove"

Procedure to Install Weld-On GET Segments

1. Preheat the segments and the bucket prior to welding. Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

2. Weld in position 416-0252 End Edge and 416-0253 End Edge with 12 mm (0.47 inch) tack welds as shown in Illustration

   Note: Ensure the end edge segments overhang by 25 mm (1.0 inch ) (A) on both sides of the bucket.

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Illustration 1	g03837792
Top view of the bucket (1) 416-0252 End Edge (2) 416-0253 End Edge (A) 25 mm (1.0 inch)

3. Measure distance (B) and distance (C) as shown in Illustration 2.

   Note: Distance (B) and distance (C) are measured from the front edge step near the center of the bucket, to the inside edge of the end edge segment.

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Illustration 2	g03837795

4. Preheat the segments to a temperature between 175°-205° C (350°-400° F) prior to removing section (3) .

   Note: Do not let the temperature fall below 175° C (350° F).

5. Remove two sections (3) as shown in Illustration 3.

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Illustration 3	g03837796
(3) Section to be removed (B) Distance measured in Step 3 (C) Distance measured in Step 3 (D) 10 Degrees

6. Preheat the segments and the bucket prior to welding.

   Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

7. Weld in position two intermediate segments (5) with 12 mm (0.47 inch) tack welds as shown in Illustration 4.

   Note: Do not weld intermediate segments (5) to end edge segments (1) and (2) .

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Illustration 4	g03837797
Top view of bucket (1) 416-0252 End Edge (2) 416-0253 End Edge (5) Intermediate segment

8. Measure distance (G) as shown in Illustration 5.

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Illustration 5	g03837940

9. Preheat the segments to a temperature between 175°-205° C (350°-400° F) prior to removing section (6) .

   Note: Do not let the temperature fall below 175° C (350° F).

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Illustration 6	g03837942
(6) Section to be removed (7) Center segment (G) Distance measured in Step 8

10. Remove two sections (6). Refer to Illustration 6.

11. Remove segment material in order to create tapered bevels on both of the newly cut ends on both the top and bottom of the segment. Bevels need to be 10 mm (0.40 inch) X 45° (Dimension (E) and (F) as shown in Illustration 7 and 8.

12. Thoroughly grind clean the area, and remove all scale and carbon.

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Illustration 7	g03838005

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Illustration 8	g03838006

13. Preheat the segments and the bucket prior to welding.

    Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

14. Weld in position with 12 mm (0.47 inch) tack welds center segment (7) as shown in Illustration 9.

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Illustration 9	g03838010

15. Using a suitable lifting device, turn the bucket over in order to weld the underside of the segments.

16. Preheat the segments and the bucket prior to welding.

    Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

17. Weld from point (K) to point (J) as shown in Illustration 10.

    Note: Start welds from the center and work to the outer edge.

    Note: Apply three to four weld passes in order to achieve a finished weld size of 12 mm (0.47 inch)

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Illustration 10	g03838015
View of the underside of the bucket

18. Weld from point (K) to point (L) as shown in Illustration 10.

    Note: Start welds from the center and work to the outer edge.

    Note: Apply three to four weld passes in order to achieve a finished weld size of 12 mm (0.47 inch)

    Note: Smoothly blend the welds at point (K) .

19. Using a suitable lifting device, turn the bucket over in order to weld the top side of the segments.

20. Preheat the segments and the bucket prior to welding.

    Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

21. Weld a 20 mm (0.78 inch) fillet weld from point (N) to point (T) as shown in Illustration 11.

22. Weld from point (R) to point (T ) as shown in Illustration 11.

    Note: Start welds from the center and work to the outer edge.

    Note: Apply several passes in order to achieve a 20 mm (0.78 inch) over a 20 mm (0.78 inch) bevel weld.

23. Weld from point (R) to point (P) as shown in Illustration 11.

    Note: Start welds from the center and work to the outer edge.

    Note: Apply several passes in order to achieve a 20 mm (0.78 inch) over a 20 mm (0.78 inch) bevel weld.

    Note: Smoothly blend the welds at point (R) .

24. Weld a 20 mm (0.78 inch) fillet weld from point (M) to point (P) as shown in Illustration 11.

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Illustration 11	g03838370

25. Preheat the segments and the bucket prior to welding.

    Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

26. Bevel weld intermediate segments (5) to center segment (7) with 10 mm (0.39 inch) bevel weld as shown in Illustration 12.

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Illustration 12	g03838429

27. Using a suitable lifting device, turn the bucket over in order to weld the underside of the segments.

28. Preheat the segments and the bucket prior to welding.

    Note: Preheat to a temperature between 175°-205° C (350°-400° F). Do not let the temperature fall below 175° C (350° F).

29. Bevel weld intermediate segments (5) to center segment (7) with 10 mm (0.39 inch) as shown in Illustration 13.

    Note: Do not weld segment (5) and the corner segments in location (U) .

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Illustration 13	g03838440

30. Using a suitable thermal covering, cover the weld areas in order to regulate the cooling of the segments and the bucket. The cooling rate needs to be less than 30° C (86° F) per hour.

31. When cooled, prime and paint the welded areas