Procedure to Install Bucket Base Edges and Cast Corners to Certain Load Haul Dump Machines {6800, 6801} Caterpillar

Load Haul Dump

R1300 (S/N: 6QW1-UP)

R1300G (S/N: LJB1-UP; NJB1-UP)

R1300G Series II (S/N: RSL1-UP)

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

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

R1600H (S/N: 9SD1-UP)

R1700 (S/N: KT41-UP)

R1700 II (S/N: 4LZ1-UP)

R1700G (S/N: SBR1-UP; XBR1-UP; 8XZ1-UP)

R2900 (S/N: BAR1-UP; 5TW1-UP)

R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)

R3000H (S/N: RCM1-UP; RCY1-UP)

Introduction

This Special Instruction covers the procedure to install bucket base edges and cast corners to the Load Haul Dump machines listed above.

Illustrations in this Special Instruction depict a generic base edge. base edges may vary depending on the type of Ground Engaging Tools (GET) installed on the bucket.

Note: R1300, R1300G, R1600, and R1600G Load Haul Dump machines do not use cast corners.

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.

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 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.

Show/hide table

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 between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

Show/hide table

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.

Show/hide table

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

Reference: Disassembly and Assembly, RENR8587, "R1300G Series II Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR6942, "R1300G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR4612, "R1300 Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR4631, "R1600 Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, KENR8508, "R1600G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR4794, "R1600G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR7843, "R1600G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, KENR6271, "R1700G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR4675, "R1700G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR4845, "R1700G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR4582, "R2900 Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR8556, "R2900G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, RENR7819, "R2900G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR7184, "R2900G Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR1483, "R3000H Load Haul Dump Machine Systems"

Reference: Disassembly and Assembly, UENR7202, "R3000H Load Haul Dump Machine Systems"

Reference: Special Instruction, REHS1841, "General Welding Procedures".

Reference: Systems Operation, RENR8594, "Machining and Welding Information for Load Haul Dumps".

Welding Requirements

For welds applied using Gas Metal Arc Welding (GMAW) 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) use AWS E7018 electrodes.

Base edges may be butter bead weld prepped. Butter bead weld prep is a layer of weld on the base edge making it possible to weld the edge onto buckets without preheating. Caterpillar recommends warming of the base edge to eliminate moisture before welding.

Procedure for R1300, R1300G, R1600, and R1600G Load Haul Dump Machines

Base Edge - Remove

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

   Note: The bucket may become unstable when removing the base edge, ensure that the bucket is suitably supported.

   Show/hide table

   Illustration 1	g06140352
   Typical example of diagonal bracing

2. Install suitable bracing between the corner and the bucket floor.

3. Preheat the area prior to arc air gouging. Refer to Table 1.
   Show/hide table

   Table 1

   Preheat °C (°F)

   Minimum 150 - 230° C (300 - 450° F)

4. Remove the base edge.

   Note: The bucket may become unstable when removing the base edge, ensure that the bucket is suitably supported.

   Note: The weight of the base edge will vary depending on the type of GET used.

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

6. Ensure that the bucket is free from dirt, grease, paint, rust, and moisture on surfaces where the base edge is to be welded.

Base Edge - Install

Show/hide table

Illustration 2	g06128094
Typical example (1) Corner

1. Grind a double bevel on corner (1) prior to installing the base edge. Repeat for the corner on the other side of the bucket.
   Show/hide table

   Illustration 3	g06256901
   (1) Corner (2) Base edge (A) Minimum 50 to 75 mm (2.0 to 3.0 inch)

2. Using a suitable lifting device, install base edge (2) in position. All joints should make hard contact between the bucket and the base edge.

   Note: The weight of the base edge will vary depending on the type of GET used.

   Note: Base edge (2) must extend beyond corner (1).

3. Preheat the weld area prior to welding. Refer to Table 2.
   Show/hide table

   Table 2

   Preheat °C (°F)

   Minimum 150 - 230° C (300 - 450° F)

4. Weld base edge (2) in position. Refer to Illustration 3 and Table 3.
   Show/hide table

   Table 3

   Item	Description
   W1	Tacking weld 25 mm (1.0 inch) in length, spaced 255 mm (10.0 inch) apart
   W2	Tacking weld 25 mm (1.0 inch)

   Show/hide table

   Illustration 4	g06128101

   Show/hide table

   Illustration 5	g06256902
   (2) Base edge (3) Floor plate

5. Weld the top side of base edge (2) in position. Refer to Illustration 4, Illustration 5, and Table 4.

   Note: Ensure that preheat temperatures are maintained. Refer to Table 2.

   Note: Ensure that interpass temperatures are not exceeded. Refer to Table 5.

   Show/hide table

   Table 4

   Item	R1300, R1300G Dimensions		R1600, R1600G Dimensions
   	Ejector	Standard	Ejector	Standard
   W3	Root pass
   W4	8 mm (0.30 inch) Bevel weld, flush with surface		12 mm (0.47 inch) Bevel weld	Bevel weld, flush with surface
   W5	Root pass
   W6	20 mm (0.80 inch) Fill weld		12 mm (0.47 inch) Bevel weld	Fill groove

   Show/hide table

   Table 5

   Interpass Temperature °C (°F)

   Maximum 260° C (500° F)

6. Using a suitable lifting device and suitable support stands, turn the bucket over. Refer to Disassembly and Assembly, "Bucket - Remove" for the approximate weight of a standard bucket.

   Note: If extra attachments have been installed on the bucket, the weight of the bucket will be increased.

   Show/hide table

   Illustration 6	g06151271
   Typical example of runoff plates installed

7. Install runoff plates at the start and at the finish of the weld joint. Refer to Illustration 6.

8. Back gouge the W3 weld from Step 5, removing all scale, carbon, and defects.

9. Weld the bottom side of base edge (2) in position. Refer to Illustration 4, Illustration 5, and Table 4.

   Note: Ensure that preheat temperatures are maintained. Refer to Table 2.

   Note: Ensure that interpass temperatures are not exceeded. Refer to Table 5.

   Note: Welds must start and stop on the runoff plates.

10. Using a suitable thermal covering, cover the weld area to regulate the cooling of the base edge. Refer to Table 6.
    Show/hide table

    Table 6

    Cooling Rate	Approximate Cooling Time
    < 50° C (120° F) / hour	4-5 hours

11. Using a suitable lifting device and suitable support stands, turn the bucket over. Refer to Disassembly and Assembly, "Bucket - Remove" for the approximate weight of a standard bucket.

    Note: If extra attachments have been installed on the bucket, the weight of the bucket will be increased.

12. Preheat the weld area prior to welding. Refer to Table 2.
    Show/hide table

    Illustration 7	g06256904
    (1) Corner (2) Base edge

13. Weld the inside and the outside of base edge (2) in position. Refer to Illustration 4, Illustration 7, Table 7, and Table 5.
    Show/hide table

    Table 7

    Item	R1300, R1300G Dimensions		R1600, R1600G Dimensions
    	Ejector	Standard	Ejector	Standard
    W7	Root pass
    W8	Root pass
    W9	16 mm (0.63 inch) Bevel weld	15 mm (0.60 inch) Bevel weld
    W10
    W11	16 mm (0.63 inch) Fillet weld	20 mm (0.80 inch) Fillet weld	16 mm (0.63 inch) Fillet weld	20 mm (0.80 inch) Fillet weld
    W712		15 mm (0.60 inch) Fillet weld		15 mm (0.60 inch) Fillet weld

14. Remove the runoff plates installed in Step 7.

15. Using a suitable thermal covering, cover the weld area to regulate the cooling of the base edge. Refer to Table 6.

Procedure for R1700G, R2900, R2900G, and R3000H Load Haul Dump Machines

Cast Corner and Base Edge - Removal

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

   Note: The bucket may become unstable when removing the base edge, ensure that the bucket is suitably supported.

   Show/hide table

   Illustration 8	g06145193
   Typical example of diagonal sidebar bracing

2. Install suitable bracing between the sidebar and bucket floor.
   Show/hide table

   Illustration 9	g06145194
   Template dimensions (A) 519 mm (20.40 inch) (B) 60 mm (2.40 inch) (C) Radius 100 mm (4.0 inch) (D) 402 mm (15.80 inch) (E) 50 mm (2.0 inch) (F) 45 mm (1.80 inch) (G) 74 mm (2.90 inch)

3. Create a template of the cast corner. Refer to Illustration 9 and reference a new cast corner.

4. Mark out the cast corner template profile on to the bucket.

5. Preheat the area prior to arc air gouging. Refer to Table 8.
   Show/hide table

   Table 8

   Preheat °C (°F)

   Minimum 150 - 230° C (300 - 450° F)

6. Remove the cast corners and base edge as an assembly.

   Note: The bucket may become unstable when removing the base edge, ensure that the bucket is suitably supported.

   Note: The weight of the base edge assembly will vary depending on the type of GET used.

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

8. Ensure that the bucket is free from dirt, grease, paint, rust, and moisture on surfaces where base edges and cast corners are to be welded.

Cast Corner to Base Edge - Install

Show/hide table

Illustration 10	g06145195
View of the underside of the base edge (1) Base edge

1. Using a suitable lifting device, turn base edge (1) so the underside is facing upward.

2. Tack weld suitable bar, angle, or tube, on the underside of base edge (1) to support and align the cast corner. Refer to Illustration 10. Repeat for the other end of the base edge.

3. Using a suitable lifting device, turn base edge (1) so the underside is facing downward.
   Show/hide table

   Illustration 11	g06145196
   (1) Base edge (2) Cast corner

4. Using a suitable lifting device, install cast corner (2) in position. The weight of cast corner (2) is approximately 113 kg (250 lb).

   Note: Use a suitable straight edge to ensure front, back, top, and bottom edges are aligned.

   Show/hide table

   Illustration 12	g06155201
   (1) Base edge (2) Cast corner

5. Weld in position cast corner (2) to base edge (1). Refer to Illustration 11, Illustration 12, and Table 9. Repeat for the cast corner on the other end of the base edge.
   Show/hide table

   Table 9

   Item	Description
   W1	Tacking weld in three places, 25 mm (1.0 inch) in length

   Show/hide table

   Illustration 13	g06145198
   Typical example of diagonal and full length bracing

6. Install suitable bracing to prevent movement of the cast corner during the welding process. Refer to Illustration 13.
   Show/hide table

   Illustration 14	g06151272
   Typical example of runoff plates installed (1) Base edge (2) Cast corner

   Show/hide table

   Illustration 15	g06155207
   Typical example of runoff plates installed (1) Base edge (2) Cast corner

7. Install runoff plates at the start and at the finish of the weld joint. Refer to Illustration 14 and Illustration 15.

8. Preheat the weld area prior to welding. Refer to Table 10.
   Show/hide table

   Table 10

   Preheat °C (°F)

   Minimum 150 - 230° C (300 - 450° F)

9. Weld cast corner (2) in position. Do not fill the groove, the groove will be filled later. Refer to Illustration 14, Illustration 15, Table 11, and Table 12. Repeat for the cast corner on the other end of the base edge.

   Note: Welds must start and stop on the runoff plates.

   Show/hide table

   Table 11

   Item	Description
   W2	Root pass
   W3	Full penetration, J groove weld.

   Show/hide table

   Table 12

   Interpass Temperature °C (°F)

   Maximum 260° C (500° F)

10. Using a suitable lifting device, turn the base edge assembly so the underside is facing upward.

11. Remove the bar, angle, or tube that was installed in Step 2.

12. Back gouge the W2 weld from Step 9, removing all scale, carbon, and defects.
    Show/hide table

    Illustration 16	g06146466
    (1) Base edge (2) Cast corner

    Show/hide table

    Illustration 17	g06155204
    (1) Base edge (2) Cast corner

13. Weld cast corner (2) in position. Fill the groove completely and grind flush. Refer to Illustration 16, Illustration 17, and Table 13. Repeat for the cast corner on the other end of the base edge.

    Note: Ensure that preheat temperatures are maintained. Refer to Table 10.

    Note: Ensure that interpass temperatures are not exceeded. Refer to Table 12.

    Note: Welds must start and stop on the runoff plates.

    Show/hide table

    Table 13

    Item	Description
    W4	Root pass
    W5	Full penetration, J groove weld.

14. Using a suitable lifting device, turn the base edge assembly so the underside is facing downward.
    Show/hide table

    Illustration 18	g06146467
    (1) Base edge (2) Cast corner

    Show/hide table

    Illustration 19	g06155205
    (1) Base edge (2) Cast corner

15. Weld cast corner (2) in position. Fill the groove completely and grind flush. Refer to Illustration 18, Illustration 19, and Table 14. Repeat for the cast corner on the other end of the base edge.

    Note: Ensure that preheat temperatures are maintained. Refer to Table 10.

    Note: Ensure that interpass temperatures are not exceeded. Refer to Table 12.

    Note: Welds must start and stop on the runoff plates.

    Show/hide table

    Table 14

    Item	Description
    W6	Full penetration, J groove weld.

16. Using a suitable thermal covering, cover the weld area to regulate the cooling of the base edge assembly. Refer to Table 15.
    Show/hide table

    Table 15

    Cooling Rate	Approximate Cooling Time
    < 50° C (120° F) / hour	4-5 hours

17. Remove the runoff plates installed in Step 7.

18. Grind welds level, ensure a smooth transition from cast corner to base edge.

Base Edge Assembly to Bucket Assembly - Install

Show/hide table

Illustration 20	g06145598
Standard bucket (1) Sidebar (2) Cast corner (3) Base edge (4) Floor plate (A) 5 Degree (B) 12 mm (0.50 inch)

Show/hide table

Illustration 21	g06145599
Ejector bucket (1) Sidebar (2) Cast corner (3) Base edge (4) Floor plate (A) 5 Degree

1. Using a suitable lifting device, install the base edge assembly to the bucket. Refer to Illustration 20, Illustration 21, and the following information.

   Note: The weight of the base edge assembly will vary depending on the type of GET used.

   Standard Bucket

   • Top of cast corner installed flush with top of sidebar.

   • Heel of cast corner installed on top of two layers of the floor plate.

   • Top of base edge installed 12 mm (0.50 inch) above top of floor plate.

   • Cast corner and sidebar installed centered to each other.

   • All joints should make hard contact between the bucket and the base edge assembly.

   Ejector Bucket

   • Top of cast corner installed lower than the sidebar.

   • Heel of cast corner installed on the bottom layer only of the floor plate.

   • Top of base edge installed flush with top of floor plate.

   • Cast corner and sidebar installed centered to each other.

   • All joints should make hard contact between the bucket and the base edge assembly.

2. Preheat the weld area prior to welding. Refer to Table 16.

   Note: Joint thickness may vary, ensure that more heat is applied to the thicker side of the joint.

   Show/hide table

   Table 16

   Preheat °C (°F)

   Minimum 150 - 230° C (300 - 450° F)

   Show/hide table

   Illustration 22	g06145600
   Typical example (2) Cast corner (3) Base edge

3. Weld the base edge assembly in position. Refer to Illustration 22 and Table 17.
   Show/hide table

   Table 17

   Item	Description
   W1	Tacking weld 25 mm (1.0 inch) in length, spaced 255 mm (10.0 inch) apart

   Show/hide table

   Illustration 23	g06145601
   Typical example

   Show/hide table

   Illustration 24	g06145987
   Weld joint for a standard bucket (2) Cast corner (3) Base edge (4) Floor plate (B) 12 mm (0.50 inch)

   Show/hide table

   Illustration 25	g06145988
   Weld joint for the R1700G ejector bucket (2) Cast corner (3) Base edge (4) Floor plate

   Show/hide table

   Illustration 26	g06145994
   Weld joint for the R2900G ejector bucket (2) Cast corner (3) Base edge (4) Floor plate

4. Weld in position the top of the base edge. Refer to Illustration 23 through Illustration 26, Table 18, and Table 19.

   Note: Ensure that preheat temperatures are maintained. Refer to Table 16.

   Note: Ensure that interpass temperatures are not exceeded. Refer to Table 20.

   Show/hide table

   Table 18

   Weld detail for a standard bucket
   Item	Description
   W2	Root pass
   W3	R1700G and R2900G 10 mm (0.40 inch) Fillet weld R3000H 12 mm (0.50 inch) Fillet weld

   Show/hide table

   Table 19

   Weld detail for a R1700G and R2900G ejector bucket
   Item	Description
   W2	Root pass
   W3	12 mm (0.50 inch) Bevel weld

   Show/hide table

   Table 20

   Interpass Temperature °C (°F)

   Maximum 260° C (500° F)

5. Using a suitable lifting device and suitable support stands, turn the bucket over. Refer to Disassembly and Assembly, "Bucket - Remove" for the approximate weight of a standard bucket.

   Note: If extra attachments have been installed on the bucket, the weight of the bucket will be increased.

   Show/hide table

   Illustration 27	g06145603
   Typical example of runoff plates installed

6. Install runoff plates at the start and at the finish of the weld joint. Refer to Illustration 27.

7. Back gouge the W2 weld from Step 4, removing all scale, carbon, and defects.

8. Weld in position the bottom of the base edge. Refer to Illustration 23 through Illustration 26, and Table 21 through Table 23.

   Note: Ensure that preheat temperatures are maintained. Refer to Table 16.

   Note: Ensure that interpass temperatures are not exceeded. Refer to Table 20.

   Note: Welds must start and stop on the runoff plates.

   Show/hide table

   Table 21

   Weld detail for a standard bucket
   Item	Description
   W4	Root pass
   W5	10 mm (0.40 inch) Bevel weld
   W6	R3000H only - completely fill groove, finish flush

   Show/hide table

   Table 22

   Weld detail for a R1700G ejector bucket
   Item	Description
   W4	Root pass
   W5	12 mm (0.50 inch) Fillet weld

   Show/hide table

   Table 23

   Weld detail for a R2900G ejector bucket
   Item	Description
   W4	Root pass
   W5	12 mm (0.50 inch) Bevel weld
   W6	12 mm (0.50 inch) Fillet weld

9. Using a suitable thermal covering, cover the weld area to regulate the cooling of the base edge assembly. Refer to Table 24.
   Show/hide table

   Table 24

   Cooling Rate	Approximate Cooling Time
   < 50° C (120° F) / hour	4-5 hours

10. Remove the runoff plates installed in Step 6. Grind end welds to allow for vertical welding.

11. Using a suitable lifting device, turn the bucket back over. Refer to Disassembly and Assembly, "Bucket - Remove" for the approximate weight of a standard bucket.

    Note: If extra attachments have been installed on the bucket, the weight of the bucket will be increased.

    Show/hide table

    Illustration 28	g06145605
    Typical example of runoff plates installed (2) Cast corner

12. Install runoff plates at the start and at the finish of the weld joint. Refer to Illustration 28.

13. Preheat the weld area prior to welding. Refer to Table 16.

    Note: Joint thickness may vary, ensure that more heat is applied to the thicker side of the joint.

    Show/hide table

    Illustration 29	g06146457
    (1) Sidebar (2) Cast corner

14. Weld the outside of cast corner (2) in position. Do not fill the groove, the groove will be filled later. Refer to Illustration 29 and Table 25.

    Note: Ensure that interpass temperatures are not exceeded. Refer to Table 20.

    Note: Welds must start and stop on the runoff plates.

    Show/hide table

    Table 25

    Item	Description
    W7	Root pass
    W8	Full penetration, J groove weld.
    W9	Root pass
    W10	Full penetration, J groove weld.
    W11	Full penetration, J groove weld.

15. Back gouge the W7 weld from Step 14, removing all scale, carbon, and defects.

16. Weld the inside of cast corner (2) in position. Fill the groove completely. Refer to Illustration 29 and Table 25.

    Note: Ensure that preheat temperatures are maintained. Refer to Table 16.

    Note: Ensure that interpass temperatures are not exceeded. Refer to Table 20.

    Note: Welds must start and stop on the runoff plates.

17. Weld the outside of cast corner (2) in position. Fill the groove completely.

18. Using a suitable thermal covering, cover the weld area to regulate the cooling of the base edge assembly. Refer to Table 24.

19. Repeat Step 14 through Step 18 for the cast corner on the other side.

20. Remove all bracing and runoff plates.