Procedure For Welding J-Series Flush Mount, Bottom Strap, And Two Strap Adapters To Bucket Base Edges{6803} Caterpillar

Introduction

This instruction gives the procedure for welding bucket tip adapters to the base cutting edge used on Loader and Excavator Buckets.

Weld Preparation

Use dry, low hydrogen E7018 weld rod or E70T-5 (do not use E70T-1) cored wire with CO₂ gas shielding. Store weld rod in 120°C (250°F) oven. Recondition exposed supply of weld rod by reheating for two hours at 260°C (500°F).

NOTE: Remove only enough weld rod for one hour of use. The moisture (water content in the air) level of exposed low hydrogen electrodes can be too high and can cause weld cracking.

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Do not weld on painted areas. The effect of gases from burned paint is a danger to the person doing the welding.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

1. Grind all weld points smooth on the base edge and on the adapters.

2. Remove all paint, rust, grease and dirt from the surfaces to be welded using a wire brush.

NOTE: Welds on painted or dirty areas can cause welds of poor quality. The result is weld embrittlement from hydrogen, porosity or lack of fusion.

High speed disc sanders are preferred over grinders as grinding on a cold, heat treated steel with a grinding wheel can generate hot spots, as indicated by a blue/black or brown color. Rapid cooling after grinding creates small surface cracks.

3. Do not weld, flame cut, gouge, or do any heavy grinding on the base edge, adapters or welds until the area to be worked on is preheated to 204°C to 260°C (400°F to 500°F).

4. Do not use gas shielded welding in windy areas or where fans are present. Poor welds can occur due to excessive cooling.

Preheat Procedure

1. Verify position of corner adapters to the bucket and then equally space the adapters across the base edge.

2. Preheat the entire adapter and an area of the base edge extending 100 mm (4 in) beyond the weld area from the side opposite to be welded. Heat to 260°C (500°F) and check the temperatures of both pieces on the side to be welded.

NOTE: To prevent losing hardness, do not exceed temperatures of 315°C (600°F). Reheat if temperatures drop below 175°C (350°F).

General Weld Procedure

1. The ground cable should be firmly attached to the base edge, not the adapters.

2. Position the work so that the weld can be applied horizontally, allowing for higher amperage and deposition rates along with a puddle of molten metal that is easier to control.

3. Good weld fusion with the adapters and base edge is extremely critical. Incomplete fusion with the adapter or base edge surfaces will result in an underbead crack. This unseen crack, with time, will propagate to the surface at the edge of the weld, leading to strap or base edge cracking and finally to breakage.

4. Caterpillar adapters have either a 30° or 45° bevel along the sides of the straps which makes it difficult to obtain the proper electrode angle and to maintain puddle control unless the base edge is positioned on end.

(A) Bevel Weld. (B) Fillet Weld.

Ideally, the bevel welds are best controlled with the base edge vertical and the adapter sides horizontal, and the fillet welds with the edge moved off from vertical as shown.

5. In most cases, it will be impossible to adjust the weld area into this position, but whatever angle the edge or bucket can be placed, it will be helpful in preventing the molten puddle from pulling away from the beveled surface. More numerous, but smaller, weld passes will help to compensate for lack of proper position.

6. When welding adapters to the top or bottom surface of a base edge, always start at locations "C" or "F", back from the leading edge, and weld towards the rear of the adapter. Never weld around the front of the edge except with a flush mount adapter. If start/stops are necessary on the final fillet weld, never stop near the adapter ends.

* On a top strap; start at "C", stop at "D". Then start at "D" and finish at "H".

* On the bottom strap; locate the stop near the midpoint between "F" and "G". Start at that point and finish the weld pass past "G" and beyond the end of the strap.

7. While the surfaces are still hot, use a disc sander to smooth rough welds or craters created by start-stops, blending them into the base edge or adapter.

Weld Procedure For Bottom Strap Adapters

Bottom Strap Adapter Weld Specifications

* The size of weld (A) is equal to the size of the groove formed by the adapter.* The size of fillet weld (B) is equal to the height of the weld groove in the adapter plus 2 mm (.08 in).* The size of weld (C) is determined by the size of the groove formed between the base cutting edge and the adapter.

Weld Procedure

* All surfaces to be welded should be flat or in a horizontal position.

* Start at the front of the cutting edge and weld towards the rear.

* All weld passes should be continuous.

* Complete all welding on the bottom side of the edge first.

1. Make the first weld (A) on each side of the adapter in the groove only.

NOTE: If the groove on the adapter continues around the front of the base edge, start the first weld pass 6 mm (.25 in) from the leading edge. Do not weld around the front of the base edge (X to Y).

2. Clean the weld after each pass.

NOTE: Do not use tools that will release air against hot welds.

3. Peen the weld with a hammer after each pass to reduce stress concentrations.

4. Recheck the temperatures of both pieces 100 mm (4 in) from the weld area before each pass.

NOTE: To prevent losing hardness, do not exceed temperatures of 315°C (600°F). Reheat if temperatures drop below 175°C (350°F).

5. Continue making weld passes alternately on each side of the adapter until the grooves are filled.

* Repeat steps 2 and 3 after each weld pass.

Weld in the direction of the large arrow.

6. Make the first fillet weld (B) starting 6 mm (.25 in) behind the leading edge and extend it 25 mm (1 in) beyond the rear of the adapter on each side.

NOTE: Do not weld across the end of the bottom leg of the adapter (P).

Stepping the fillet welds.

The large arrow shows the direction of the weld pass.

7. Continue making fillet weld passes alternately on each side of the adapter stopping each pass slightly in front of the previous one. Feather the welds one on top of the other until the correct fillet weld size has been attained (see above illustration).

* Repeat steps 2 and 3 after each weld pass.

NOTE: The above illustration is intended to show the preheat and the weld sequence for the adapters only. It is not intended to show any specific type of adapter or cutting edge. Weld in a similar sequence to decrease possible distortion.

8. Repeat steps 1 thru 7 for the remaining adapters.

9. Complete all the welding on the top side of the base edge.

10. Repeat steps 1 thru 5.

11. Make the bevel groove cross weld (C).

Weld in the direction of the large arrow.

12. Make the first fillet weld (B) starting 6 mm (.25 in) behind the leading edge and extend it 25 mm (1 in) beyond the rear of the adapter on each side.

Stepping the fillet welds.

The large arrow shows the direction of the weld pass.

13. Continue making fillet weld passes alternately on each side of the adapter stopping each pass slightly in front of the previous one. Feather the welds one on top of the other until the correct fillet weld size has been attained (see above illustration).

* Repeat steps 2 and 3 after each weld pass.

NOTE: The above illustration is intended to show the preheat and the weld sequence for the adapters only. It is not intended to show any specific type of adapter or cutting edge. Weld in a similar sequence to decrease possible distortion.

14. Repeat steps 10 thru 13 for the remaining adapters.

15. Put a cover over the base cutting edge and let it cool slowly.

Weld Procedure For Flush Mounted Adapters

Flush Mounted Adapter Weld Specifications

(1) Soft iron wire.

* The size of weld (A) is equal to the size of the groove formed by the adapter.* The size of fillet weld (B) is equal to the height of the weld groove in the adapter plus 2 mm (.08 in).* The size of fillet weld (C) is equal to fillet weld (B).* The size of weld (D) is determined by the size of the groove formed between the base cutting edge and the adapter.

In situations where flush mount adapters are being welded on to non-Caterpillar or extra sharp base edges, it may be necessary to modify the front of the base edge so that a properly sized weld can be applied to the underside of the adapter.

Cut area (F), minimum flat, as shown.

NOTE: Extend the flat height 25 mm (1 in) to 51 mm (2 in) beyond the adapter width and gradually decrease the cut to the sharp edge. Grind all surfaces smooth.

Weld Procedure

* All surfaces to be welded should be flat or in a horizontal position.

* Start at the front of the cutting edge and weld towards the rear.

* All weld passes should be continuous.

* Complete all welding on the top side of the base cutting edge first.

1. Make the first weld (A) on each side of the adapter in the groove only.

2. Clean the weld after each pass.

NOTE: Do not use tools that will release air against hot welds.

3. Peen the weld with a hammer after each pass to reduce stress concentrations.

4. Recheck the temperatures of both pieces 100 mm (4 in) from the weld area before each pass.

NOTE: To prevent losing hardness, do not exceed temperatures of 315°C (600°F). Reheat if temperatures drop below 175°C (350°F).

5. Continue making weld passes alternately on each side of the adapter until grooves are filled.

* Repeat steps 2 and 3 after each weld pass.

Weld in the direction of the large arrow.

6. Make the first fillet weld (B) and (C) starting at the leading edge and extend it 25 mm (1 in) beyond the rear of the adapter on each side.

NOTE: Do not weld across the end of the adapter (P).

Stepping the fillet welds.

The large arrow shows the direction of the weld pass.

7. Continue making fillet weld passes alternately on each side of the adapter stopping each pass slightly in front of the previous one. Feather the welds one on top of the other until the correct fillet weld size has been attained (see above illustration).

* Repeat steps 2 and 3 after each weld pass.

NOTE: The above illustration is intended to show the preheat and the weld sequence for the adapters only. It is not intended to show any specific type of adapter or cutting edge. Weld in a similar sequence to decrease possible distortion.

8. Repeat steps 1 thru 7 for the remaining adapters.

9. Complete all the welding on the bottom side of the base edge.

10. Make the bevel groove cross weld (D).

11. Repeat step 10 for the remaining adapters.

NOTE: Weld in a sequence similar to the above illustration to decrease possible distortion.

12. Put a cover over the base cutting edge and let it cool slowly.

Weld Procedure For Two Strap Adapters

Two Strap Adapter Weld Specifications

(1) Excavator adapter. (2) Bucket adapter.

* The size of weld (A) is equal to the size of the groove formed by the adapter.* The size of fillet weld (B) is equal to the height of the weld groove in the adapter plus 2 mm (.08 in).* The size of fillet weld (C) is equal to fillet weld (B).

Weld Procedure

* All surfaces to be welded should be flat or in a horizontal position.

* Start at the front of the cutting edge and weld towards the rear.

* All weld passes should be continuous.

* Complete all welding on the side with the longer strap first.

1. Make the first weld (A) on each side of the adapter in the groove only.

NOTE: If the groove on the adapter continues around the front of the base edge, start the first weld pass 6 mm (.25 in) from the leading edge. Do not weld around the front of the base edge (X to Y).

2. Clean the weld after each pass.

NOTE: Do not use tools that will release air against hot welds.

3. Peen the weld with a hammer after each pass to reduce stress concentrations.

4. Recheck the temperatures of both pieces 100 mm (4 in) from the weld area before each pass.

NOTE: To prevent losing hardness, do not exceed temperatures of 315°C (600°F). Reheat if temperatures drop below 175°C (350°F).

5. Continue making weld passes alternately on each side of the adapter until the grooves are filled.

* Repeat steps 2 and 3 after each weld pass.

Weld in the direction of the large arrow.

6. Make the first fillet weld (B) and (C) starting 6 mm (.25 in) behind the leading edge and extend it 25 mm (1 in) beyond the rear of the adapter on each side.

NOTE: Do not weld across the end of the adapter (P).

Stepping the fillet welds.

The large arrow shows the direction of the weld pass.

7. Continue making fillet weld passes alternately on each side of the adapter stopping each pass slightly in front of the previous one. Feather the welds one on top of the other until the correct fillet weld size has been attained (see above illustration).

* Repeat steps 2 and 3 after each weld pass.

NOTE: The above illustration is intended to show the preheat and the weld sequence for the adapters only. It is not intended to show any specific type of adapter or cutting edge. Weld in a similar sequence to decrease possible distortion.

8. Repeat steps 1 thru 7 for the remaining adapters.

9. Complete all welding on the opposite side of the base edge.

10. Repeat steps 1 thru 8.

11. Put a cover over the base cutting edge and let it cool slowly.