- Wheel Tractor-Scraper:
- 621H (S/N: DBK1-UP; EAZ1-UP)
- 627H (S/N: LCT1-UP; DBW1-UP)
Introduction
ReferenceDisassembly and Assembly, KENR8884, "Apron Lift - Remove and Install"
ReferenceDisassembly and Assembly, KENR8884, "Apron - Remove and Install"
ReferenceDisassembly and Assembly, KENR8884, "Ejector Cylinder - Remove and Install"
ReferenceDisassembly and Assembly, KENR8884, "Ejector - Remove and Install"
ReferenceSpecial Instructions, REHS1841, "General Welding Procedures"
ReferenceSpecial Instructions, SEBD0512, "Caterpillar Service Welding Guide"
This instruction will cover the repair of the cutting edge and scraper floor for the machines that are listed above. Under certain situations, the ejector can become damaged by debris in certain conditions.
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. |
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. |
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Welding Details
ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.
All welders must be qualified for fillet and groove welding as outlined in the current ANSI/AWS D1.1, or D14.3, or comparable International Welding Standard. The welding operator must also have used the welding process during the last six months or be re-certified for this process before welding. Personal protection should be provided to assure that total weld fume in the operators breathing zone is within safe limits.
Shielded Metal Arc Welding
The Shielded Metal Arc Welding (SMAW) process may be used with the E7018 (ANSI/AWS A5.1) welding electrode. The weld that will be deposited by these electrodes will have the following mechanical properties.
| Tensile strength | 480 MPa (69600 psi) |
| Yield strength | 400 MPa (58000 psi) |
| Elongation | 22% |
| Impact toughness | 27 N·m (20 lb ft) |
These low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F) when the electrodes are not being used. Scrap the electrodes if the electrodes get damp.
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.
The following chart relates to the electrode diameter and approximate current settings for welding.
| Diameter | Current |
3.2 mm (0.1260 inch) |
70-140 |
4 mm (0.16 inch) |
110-180 |
4.8 mm (0.19 inch) |
190-270 |
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.
Flux Cored Arc Welding
The Flux Cored Arc Welding (FCAW) process may be used with the E71T-1 (AWS A5.20) welding electrode. The FCAW process may also be used with shielding gas. The weld that will be deposited by these electrodes will have the following mechanical properties.
| Tensile strength | 480 MPa (69600 psi) |
| Yield strength | 400 MPa (58000 psi) |
| Elongation | 22% |
| Impact toughness | 27 N·m (20 lb ft) |
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.
For a 1.1 mm (0.045 inch) electrode, the typical welding parameters should be the following.
| Wire Feed Speed | Voltage | Approximate Amperage |
| MIN 175 Inches Per Minute. | 22-24 | 130 |
| MID 350 Inches Per Minute. | 26-28 | 210 |
| MAX 425 Inches Per Minute. | 29-31 | 275 |
For a 1.3 mm (0.052 inch) electrode, the typical welding parameters should be the following.
| Wire Feed Speed | Voltage | Approximate Amperage |
| MIN 200 Inches Per Minute. | 22-24 | 185 |
| MID 300 Inches Per Minute. | 25-27 | 245 |
| MAX 425 Inches Per Minute. | 28-30 | 295 |
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.
| Weld Specifications | |
| W1 | 6 mm (0.24 inch) flare bevel weld |
| W2 | 16 mm (0.63 inch) groove weld |
| W3 | 8 mm (0.32 inch)bevel groove weld |
| W4 | 6 mm (0.24 inch) fillet weld |
| W5 | 8 mm (0.32 inch) fillet weld |
| W6 | 10 mm (0.4 inch) bevel weld |
| W7 | Square groove |
| W8 | 12 mm (0.47 inch) groove weld |
| W9 | 6 mm (0.24 inch) groove weld |
Note: All vertical welds will be welded with a vertical up technique.
Inspect the Machine to Verify That Rework is Required
The scraper bowl floor may be considered for replacement when any of the following situations apply.
- The plate to which the cutting edges attach, is bent to the point where cutting edge bolts come loose and the plate cannot be replaced.
- If the bottom surface of the floor dented/bent significantly with six or more dents larger than 152.4 mm (6 inch)6 inch, and deeper than 25.4 mm (1 inch).
- If the bottom faces of floor are worn, to less than 3 mm (0.12 inch). Check the floor at multiple locations by measuring with a 168-7721 Indicator . Refer to Tool Operating Manual, NEHS0730-03, " 168-7720 Ultrasonic Wear Indicator III Group" for information regarding proper operation.
- If the entire floor is bent more than 19 mm (0.75 inch) of an inch and after adjusting the ejector floor and side rollers per the Owner Manual, the ejector still rubs hard on the floor.
Bowl Rework
Refer to the Disassembly and Assembly, KENR8884 Manual as needed.
Required Parts
| Consists of 417-5045 Ejector Repair Kit | |||
| Callout | Part Number | Description | Quantity |
| 1 | 441-6988 | Bottom As | 1 |
| 2 | Dealer Fabricated | Plate | 1 |
| 3 | Dealer Fabricated | Plate | 1 |
| 4 | Dealer Fabricated | Plate | 1 |
| 5 | Dealer Fabricated | Plate | 1 |
| 6 | Dealer Fabricated | Plate | 4 |
| 7 | Dealer Fabricated | Plate | 2 |
| 8 | Dealer Fabricated | Plate | 1 |
| 9 | Dealer Fabricated | Plate | 1 |
| 10 | Dealer Fabricated | Plate | 1 |
| 11 | Dealer Fabricated | Plate | 1 |
| 12 | Dealer Fabricated | Gusset | 2 |
| 13 | Dealer Fabricated | Gusset | 2 |
| 14 | Dealer Fabricated | Plate | 2 |
| 15 | Dealer Fabricated | Plate | 2 |
| 16 | Dealer Fabricated | Block | 6 |
| 17 | Dealer Fabricated | Block | 2 |
| 18 | Dealer Fabricated | Lifting Eye | As Required |
Dealer Fabricated Parts
All dealer fabricated parts shown below are to be made using the following material: ASTM A572 Grade 42 or 50 Steel
Plate 2
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| Illustration 1 | g03645337 |
(A) 11 mm (0.4 inch) (B) 16 mm (0.6 inch) (C) 570 mm (22.4 inch) (D) 554 mm (21.8 inch) (E) 83 mm (3.3 inch) (F) 656 mm (25.8 inch) (G) 662 mm (26.1 inch) (H) 5.4 mm (0.21 inch) (J) 75 mm (3.0inch) | |
Plate 3
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| Illustration 2 | g03645334 |
(A) 570 mm (22.4 inch) (B) 554 mm (21.8 inch) (C) 11 mm (0.4 inch) (D) 16 mm (0.6 inch) (E) 45 ° (F) 662 mm (26.1 inch) (G) 570 mm (22.4 inch) (H) 554 mm (21.8 inch) (J) 5.4 mm (0.2 inch) (K) 75 mm (3.0 inch) (L) 656 mm (25.8 inch) (M) 83 mm (3.3 inch) | |
Plate 4
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| Illustration 3 | g03646108 |
(A) 53 mm (2.09 inch) (B) 44.5 mm (1.75 inch) (C) 29.1 mm (1.15 inch) (D) 15.4 mm (0.61 inch) (E) 960.3 mm (37.81 inch) (F) 903 mm (35.6 inch) (G) 800 mm (31.5 inch) (H) 8.5 mm (0.33 inch) (J) 154.3 mm (6.07 inch) (K) 150 mm (5.9 inch) (L) 142.1 mm (5.60 inch) (M) 127.3 mm (5.01 inch) (N) 115.6 mm (4.55 inch) (P) 24.9 mm (0.98 inch) (Y) Radius 2590 mm (102 inch) (Z) Radius 12520 mm (493 inch) (ZZ) Radius 7274.9 mm (286 inch) | |
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| Illustration 4 | g03646110 |
(R) 582.2 mm (22.92 inch) (S) 594 mm (23.4 inch) (T) 544 mm (21.4 inch) (U) 444 mm (17.5 inch) (V) 477.5 mm (18.80 inch) (W) 550 mm (21.7 inch) (X) 24.9 mm (0.98 inch) | |
Plate 5
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| Illustration 5 | g03646386 |
(A) 99 mm (3.9 inch) (B) 477.2 mm (18.79 inch) (C) 6 mm (0.2 inch) (D) 71 mm (2.8 inch) (E) 139.6 mm (5.5 inch) (F) 45 ° (G) 584 mm (23.0 inch) (H) 450 mm (17.7 inch) (J) 550 mm (21.7 inch) (K) 614.5 mm (24.19 inch) | |
Plate 6
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| Illustration 6 | g03647005 |
(A) 8.5 mm (0.33 inch) (B) 44.5 mm (1.75 inch) (C) 29.1 mm (1.15 inch) (D) 15.4 mm (0.61 inch) (E) 53 mm (2.10 inch) (F) 960.3 mm (37.81 inch) (G) 903 mm (35.55 inch) (H) 800 mm (31.5 inch) in two places. (J) 671.4 mm (26.43 inch) (K) 282.6 mm (11.13 inch) (L) 154.3 mm (6.07 inch) (M) 143.4 mm (5.65 inch) (N) 8 mm (0.31 inch) in seven places. (P) Radius 2590 mm (101.97 inch) (R) Radius 7274.9 mm (286.41 inch) (S) Radius 12520 mm (492.91 inch) (T) 24.8 mm (0.98 inch) (U) 127.7 mm (5.03 inch) (V) 142.1 mm (5.60 inch) | |
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| Illustration 7 | g03663036 |
(AA) 24.9 mm (0.98 inch) (BB) 588 mm (23.10 inch) (CC) 75.2 mm (2.96 inch) (DD) 477.5 mm (18.80 inch) (EE) 444 mm (17.5 inch) (FF) 544 mm (21.5 inch) (GG) 585.2 mm (23.04 inch) (HH) 424.6 mm (16.72 inch) (HH) 424.6 mm (16.72 inch) (JJ) 425.3 mm (16.74 inch) | |
Plate 7
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| Illustration 8 | g03646563 |
(A) 99 mm (3.9 inch) (B) 477.2 mm (18.8 inch) (C) 139.6 mm (5.5 inch) (D) 71 mm (2.8 inch) (E) 550 mm (21.7 inch) (F) 450 mm (17.7 inch) (G) 15 mm (0.6 inch) (H) 584 mm (23.0 inch) (J) 614 mm (24.2 inch) (K) 45 ° (L) 6 mm (0.2 inch) | |
Plate 8
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| Illustration 9 | g03645499 |
(A) 43.4 mm (1.71 inch) (B) 35.8 mm (1.41 inch) (C) 7.9 mm (0.31 inch) (D) 23.1 mm (0.91 inch) (E) 12.7 mm (0.50 inch) (F) 1.3 mm (0.05 inch) (G) 430.5 mm (16.95 inch) (H) 395 mm (15.55 inch) (J) 360.5 mm (14.19 inch) (K) 9.2 mm (0.36 inch) (L) 173.9 mm (6.85 inch) (M) 161 mm (6.34 inch) (N) 86.3 mm (3.40 inch) (P) 68.2 mm (2.69 inch) (R) 64.2 mm (2.53inch) (S) 18.2 mm (0.72inch) (T) 122.5 mm (4.82inch) (U) 127.6 mm (5.02 inch) (V) 360.6 mm (14.20inch) (W) 395 mm (15.55 inch) (X) 252.1 mm (9.93 inch) (Y) Radius1238.5 mm (48.76 inch) (Z) Radius 3626.9 mm (142.79 inch) | |
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| Illustration 10 | g03645503 |
(ZZ) 175 mm (6.89 inch) (AA) 219.9 mm (8.66 inch) (BB) 6 mm (0.24 inch) (CC) 293.6 mm (11.56 inch) (DD) 184.9 mm (7.28 inch) (EE) 150.5 mm (5.93 inch) (FF) 150.5 mm (5.93nch) | |
Plate 9
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| Illustration 11 | g03662832 |
(A) 43.7 mm (1.72 inch) (B) 35.8 mm (1.41 inch) (C) 23.1 mm (0.91 inch) (D) 12.7 mm (0.50 inch) (E) 5 mm (0.2 inch) (F) 7.6 mm (0.30 inch) (G) 430.5 mm (16.95 inch) (H) 395.5 mm (15.57 inch) (J) 360.5 mm (14.19 inch) (K) 173.9 mm (6.85 inch) (L) 161 mm (6.3 inch) (M) 112.6 mm (4.43 inch) (N) 37.1 mm (1.5 inch) (P) 26.6 mm (1.05 inch) (R) 17.6 mm (0.69291 inch) (S) 28.9 mm (1.14 inch) (T) 32.7 mm (1.29 inch) (U) 122.5 mm (4.82 inch) (V) 127.6 mm (5.021 inch) (W) 360.6 mm (14.20 inch) (X) 395.5 mm (15.57 inch) (Y) Radius 1238.5 mm (48.76 inch) (Z) Radius 3626.9 mm (142.79 inch) (ZZ) 7 mm (0.3 inch) | |
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| Illustration 12 | g03647067 |
(AA) 17.6 mm (0.69 inch) (BB) 50.5 mm (1.99 inch) (CC) 293.6 mm (11.56 inch) (DD) 6 mm (0.2 inch) (EE) 219.9 mm (8.66 inch) | |
Plate 10
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| Illustration 13 | g03646492 |
(A) 147.1 mm (5.8 inch) (B) 165 mm (6.5 inch) (C) 2 mm (0.1 inch) (D) 6 mm (0.2 inch) (E) 45 ° (F) 191 mm (7.5 inch) (G) 169.1 mm (6.7 inch) (H) 190 mm (7.5 inch) (J) 5 mm (0.2 inch) (K) 14.3 mm (0.6 inch) (L) 181.4 mm (7.1 inch) | |
Plate 11
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| Illustration 14 | g03646111 |
(A) 2 mm (0.1 inch) (B) 20 mm (0.8 inch) (C) 165 mm (6.5 inch) (D) 147.1 mm (5.79 inch) (E) 161.4 mm (6.35 inch) (F) 9.32 mm (0.37 inch) (G) 45 ° (H) 14.3 mm (0.56 inch) (J) 5 mm (0.2 inch) (K) 190 mm (7.5 inch) (L) 169.1 mm (6.66 inch) (M) 191 mm (7.5 inch) | |
Gusset 12
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| Illustration 15 | g03645341 |
(A) 130 mm (5.1 inch) (B) 10 mm (0.4 inch) (C) 20 mm (0.8 inch) (D) 20 mm (0.8 inch) (E) 210 mm (8.3 inch) | |
Gusset 13
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| Illustration 16 | g03645340 |
(A) 452.3 mm (17.81 inch) (B) 441.9 mm (17.40 inch) (C) 10 mm (0.39 inch) (D) 161.5 mm (6.36 inch) (E) 12 mm (0.47 inch) (F) 425.9 mm (16.77 inch) (G) 438.9 mm (17.28 inch) (H) 35.8 mm (1.41 inch) (J) 169.9 mm (6.69 inch) | |
Plate 14
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| Illustration 17 | g03645342 |
(A) 800 mm (31.5 inch) (B) 6 mm (0.2 inch) (C) 734 mm (28.9 inch) (D) 598 mm (23.5 inch) (E) 4 mm (0.2 inch) (F) 62 mm (2.4 inch) (G) 587 mm (23.1 inch) (H) 660 mm (26.0 inch) (J) 550 mm (21.7 inch) (K) 450 mm (17.7 inch) (L) 36 mm (1.4 inch) (M) 14.6 mm (0.57 inch) | |
Plate 15
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| Illustration 18 | g03646112 |
(A) 87.3 mm (3.44 inch) (B) 50.5 mm (1.99 inch) (C) 3 mm (0.1 inch) (D) 53.4 mm (2.1 inch) (E) 5 mm (0.2 inch) (F) 30 mm (1.2 inch) (G) 1.5 mm (0.06 inch) (H) 4.1 mm (0.16 inch) (J) 38.4 mm (1.51 inch) (K) 40 mm (1.6 inch) (L) 85 mm (3.3 inch) (M) 53.6 mm (2.11 inch) (N) 53.6 mm (2.11 inch) | |
Block 16 and 17
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| Illustration 19 | g03654057 |
(A) 75 mm (3 inches) (B) 25 mm (1.0 inch) (C) 25 mm (1.0 inch) | |
18 Lifting Eye
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| Illustration 20 | g03672117 |
Use the tubing that is being used to make the cross bracing. Refer to table 8 (A) 12 mm (0.5 inch) (B) 75 mm (3 inch) (C) 75 mm (3 inch) (D) 6 mm (0.24 inch) | |
Disassembly
- Place rear of push frame on jack stands. The scraper wheels and tires can be left on.
- Remove the apron from the front of the bowl for ease of removing the ejector.
- Remove all attachments to the cutting edge area that will interfere with the removal of the ejector and removal/installation of the floor.
- Remove the ejector out of the bowl, and return ejector cylinder back to closed position to allow access to the back of the bowl floor. The apron cylinder can be suspended temporarily with chains.
- Block up the front of the push frame and front of bowl to a level floor that is about 1 m (1 yd) above the ground. Block the position at the front of the push frame. This position will help prevent the lower push frame members from moving when the bowl floor is removed in later steps.
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| Illustration 21 | g03647165 |
Points of support for the scraper | |
- Remove any bowl liner plates that are positioned against the top of the floor.
Prepare and Install Cross Braces For Bowl Walls
Cut to length the braces that will hold the walls of the bowl in place.
| Material Cut List | ||||
| Item | Name | Qty | Material | Length |
| A | Push Frame Brace | 1 | 75x75x6 mm square tubing 3x3x.25 inch square tubing |
1112 mm (43.78 inch) |
| B | Inter Bracing | 2 | 75x75x6 mm square tubing 3x3x.25 inch square tubing |
700 mm (27.6 inch) |
| C | Bowl Brace | 2 | 75x75x6 mm square tubing 3x3x.25 inch square tubing |
3048 mm (120 inch) |
Perform the Welding Fabrication
When removing gusset and transition plate welds with the air-carbon arc gouging process, the transition and gusset plates, or old floor assembly are to be sacrificed. Under no circumstances should the push frame legs be excessively gouged. When gouging, find the weld joint separation crack then favor the gussets, transition plates, or floor. For optimal control use ?" diameter gouging electrode.
For the following sequences in this section, perform the indicated work on one side, then go do the same step to the other side. This rotation will help balance any residual stresses that are going to be released while cutting.
Framework Assembled Inside the Bowl
Do Not weld this assembly prior to installation into the bowl.
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| Illustration 22 | g03647564 |
The width between (B) and (D) can vary to allow the necessary clearance. | |
Fabricate this brace assembly while inside of the bowl. The brace assembly will look like the one pictured above.
- Assemble and weld the bracing components while inside the bowl. The bracket assembly will not fit inside the push frame rails if pre-assembled. Place a 6 mm (0.25 inch) fillet weld of 50 mm (1.96 inch) length on the square tubing on the two sides opposite each other. Welding the corners is not required.
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| Illustration 23 | g03647656 |
Fillet welds are 6 mm (0.25 inch) and a minimum length of 50 mm (2 inches). | |
- Tack weld blocks (16) and blocks (17) onto the side wall of bowl as a reference point for the new floor. Remove fillet welds that hold the floor to the side of the bowl in block locations prior to tacking the blocks into place.
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| Illustration 24 | g03648037 |
Locating the bowl floor | |
- As an aid when locating new floor, note cutting edge support corner location block (16) of router bit support plate.
- Inspect bottom edge to ensure enough material for new weld. Excessive wear to the bowl side requires being built up enough to accommodate fillet weld. There should be approximately 18 mm (0.7 inch) of material or a minimum of 11 mm (0.43 inch) of material. See above
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| Illustration 25 | g03648084 |
Inspection of the bottom edge | |
- Remove weld from both gussets (G) and gusset (H) on the outer edge of the floor plate using an air arc.
- Remove gusset and transition plate welds with the air-carbon arc gouging process. The transition and gusset plates, or old floor assembly are to be sacrificed. Under no circumstances should the push frame legs be excessively gouged. When gouging, find the weld joint separation crack then favor the gussets, transition plates, or floor. For optimal control use 6.4 mm (0.25 inch) diameter gouging electrodes.
- Measurement (J) needs to be taken on the bottom gusset plate as a reference for locating the new plate. Repeat this step on the side. Measure 860 mm from the base of the floor back.
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| Illustration 26 | g03648240 |
Measure gusset on both sides before removing (J) 860 mm (33.9 inch) | |
- Remove the existing vertical 323-6330 Gusset (K). Sacrifice the marked gusset (K) being removed and not the vertical gusset.
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| Illustration 27 | g03648293 |
Existing 323-6330 Gusset (K) . | |
- Remove gusset (L). Sacrifice gusset (L) being removed and save green vertical gusset.
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| Illustration 28 | g03648307 |
Existing vertical 323-6329 Gusset (L) | |
- Remove the existing 335-7638 Plate (M) from the left side of the scraper. Then remove the existing 323-6317 Plate from the right side of the scraper. Sacrifice the part being removed and not the green vertical gusset.
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| Illustration 29 | g03648313 |
Existing 335-7638 Plate . | |
- Remove the existing 342-9163 Plate (N) from the left side of the scraper. Then remove the existing 339-3515 Plate from the right side of the scraper. Sacrifice the part being removed and not the green vertical gusset.
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| Illustration 30 | g03648316 |
Remove existing 342-9163 left gusset (N) . | |
- Remove one 344-7682 Plate . Sacrifice the part being removed and not the green rolled rail section.
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| Illustration 31 | g03648334 |
Remove one 344-7682 Plate | |
- Remove the existing 342-9164 Plate (P) on the left side of the machine. Sacrifice the part being removed and not the green vertical gusset. Then remove the existing 335-7642 from the right side of the machine. Sacrifice the part being removed and not the green vertical gusset.
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| Illustration 32 | g03648340 |
Existing 342-9164 left gusset | |
- Remove the existing 335-7638 Plate (R) on the left side of the machine. Sacrifice the part being removed and not the green rolled rail section. Sacrifice the part being removed and not the green rolled rail section. Then remove the existing plate on the right side of the machine.
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| Illustration 33 | g03648353 |
335-7638 Plate (R) | |
- Remove existing 323-6321 Plate (S) on the left side. Sacrifice the part being removed and not the green rolled rail section. The plate extends under the green rolled rail section. then remove the plate from the right side.
 | |
| Illustration 34 | g03648365 |
323-6321 Plate (S) | |
- Remove the existing 443-3438 Plate from the left and the 443-3437 Plate from the right. Sacrifice the green part and not the gray vertical bowl wall member.
 | |
| Illustration 35 | g03648377 |
View of the left gusset | |
- Remove welds (T) and (U) on the bottom of the existing floor, that connect the floor to the bowl sides. Sacrifice the floor as much as possible, but keep in mind to remove all material from the side of the bowl. If all material is not removed then, the existing bottom assembly may get snagged on the excess weld when dropping it out from the bottom. Any gouging in the side will be repaired later before putting in the new bowl.
 | |
| Illustration 36 | g03648438 |
Bottom floor welds | |
- Place appropriate supports/blocking underneath the bowl floor, then when the floor is lowered from the bowl the floor will not damage the working surface.
- Remove weld holding the existing 339-3515 Plate (V) to the floor plate on the left side of the machine. Then remove the weld holding the existing 339-3517 Plate to the floor plate on the right side of the machine. Sacrifice the floor and preserve the push frame.
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| Illustration 37 | g03648448 |
Remove Welds Holding Push Frame to the Floor | |
- Remove weld holding back of floor to the bowl wall on both sides.
 | |
| Illustration 38 | g03661020 |
- After welds are removed from back of floor on both sides, tack weld one block (17) on each side of the rear of the floor. These blocks will provide a stop for locating the new floor.
 | |
| Illustration 39 | g03648487 |
After removing the welds on the back of floor insert locating blocks on each side. | |
- Manufacture four lifting eyes (18) . Weld four lifting eyes (18) to the top of the bottom assembly using a 6 mm (0.24 inch) fillet weld all around. See red circles for the lifting lug configuration. Use an insulating block, lift rigging until there is no slack, and little upwards force. Snug the lifting cable so that when the final welds on top are cut away there is no risk of the bottom assembly falling.
 | |
| Illustration 40 | g03672577 |
(18) example of one lifting eye attached to the back of the bottom assembly. | |
 | |
| Illustration 41 | g03672531 |
Front lift eyes can be replaced with cat part numbers. The rear two lifting eyes can be replaced with one lifting eye. Remove all welds that are attaching the top of floor to the bowl sides. Sacrifice the floor, and preserve the bowl sides. | |
 | |
| Illustration 42 | g03648490 |
- Place two Portable Air/Hydraulic bottle jacks with a long enough whip for operating a safe distance from the floor. One inline vertically with each supporting brace, but just above floor level. The Portable Air/Hydraulic bottle jacks are in case the floor does not drop out. In that case slightly spread the bowl.
- If a crane was used, lower the floor out of the bowl, and remove the floor from the side with applicable equipment. If the blocking method was used, pull the blocks out from underneath the floor with capable equipment, then remove the floor out the side. Both of these methods can be done safely. If the floor does not fall out, then two people will have to slightly spread the bowl walls simultaneously. Minimal spreading should be required. If spreading the bowl walls slightly does not work then someone needs to inspect for remaining welded areas using Extreme Caution.
| NOTICE |
|---|
If spreading the bowl walls slightly does not work then someone needs to inspect for remaining welded areas using Extreme Caution. |
Install the New Floor
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| Illustration 43 | g03653036 |
- Repair any areas of the bowl sides that were gouged, and sand to a flush surface.
- Weld the spacer blocks (F) using 50 mm (2 inch) long vertical welds. There will be (6) blocks with three blocks per bowl side. These spacer blocks were positioned prior to removing the bottom.
- Uncrate new 441-6988 floor assembly and place on blocks or short saw horses
Note: The new bottom assembly weighs 892 kg (1966.5 lb)
- Check overall width at front and rear end of new floor and compare with distance between bowl sides.
- It might be necessary to spread bowl side opening slightly when positioning the new floor.
- If the bowl is too wide, it may be necessary to pull the frame together ensuring a gap of 2 mm (0.08 inch) or less.
- With a combination square or 150 mm (6 inch) machinist square, check both sides of floor assembly to make sure upper and lower floor plates are even and not offset. An offset plate condition can create interference when locating the floor assembly between bowl sides.
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| Illustration 44 | g03654117 |
- Remove paint from all weld areas, to include areas on top plate for lifting eyes.
- Fabricate three lifting eyes from 12 mm (0.48 inch) plate then locate about the floor top plate center line and weld all around. Placement of the lifting eyes must allow a level pick-up.
- Move floor assembly and place on floor next to bowl. Use chains and a fork-lift, drag floor assembly under bowl to approximate position. Using three hook chains, test lift to see if floor is level when suspended from hoist. Adjust lift chains as required.
- Lift the new bottom assembly into position, by lifting until it contacts six blocks (16) of the locating blocks. Push the new bottom assembly back into the push frame to locate the bottom assembly fore and aft.
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| Illustration 45 | g03653140 |
- With the bottom assembly lifted in place, release the pressure if any against the side walls from the portable hydraulics, and then recheck the alignment. Read adjust the alignment if necessary.
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| Illustration 46 | g03653256 |
- Tack both joints to the new bottom assembly (1) and the push frame on both the top and bottom. It may be necessary to flatten plate (14). Plate (14) is the hidden part that is outlined in red. Ensure a root opening of 3 mm (0.12 inch) or less along the edge that contacts bottom assembly (1) .
- Place blocks under the four corners causing upward pressure against the locators. Make the bottom assembly stable enough that it cannot shift around when walking on top of it.
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| Illustration 47 | g03653276 |
- Place several solid tacks on both sides of the top of the floor connecting the top of the floor to the bowl sides.
- Weld the back of the bottom assembly (1) to the push frame using a 8mm groove/fillet weld on the top and bottom.
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| Illustration 48 | g03662123 |
- Make a 12 mm (0.47 inch) Bevel Groove weld from (B) to (C) .
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| Illustration 49 | g03662137 |
- Weld a 10 mm (0.39 inch) 3-pass Bevel-Groove from (A) to (B) .
- Weld (A) to (D) using 6 mm (0.24 inch) weld. Use the back step welding method, stepping every 300 mm (11.8 inch). Alternate sides after every step, and skip where the spacer blocks currently are. Weld a 6 mm (0.24 inch) fillet weld down the remaining length of the bowl floor to the bowl side.
- With the floor blocked, remove the rigging devices.
- Cut off the locator blocks (16), and repair gouging to the bowl sides. Then finish welding the top of the floor using a 6 mm (0.24 inch) weld.
- Using the back step method, stepping every 300 mm (11.8 inch). Alternate sides after every step, weld both sides of the bottom side of the floor to the bowl sides using a 6 mm (0.24 inch) fillet weld. Weld the bottom from (E) to (F) .
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| Illustration 50 | g03653286 |
- Weld in the additional cutting edge plates (2) on the left side and (3) on the right side. For both plates use an 8 mm (0.32 inch) fillet across the floor and down the cutting edge from location (G) to (H). Then on the outside, place a 12 mm (0.47 inch) 3-pass fillet from (J) to (K) .
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| Illustration 51 | g03653322 |
- Weld the end of the floor to the bowl side using a 6 mm (0.24 inch) fillet weld. Extend the weld from (L) to (M) on both sides of the bowl.
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| Illustration 52 | g03653336 |
- Locate plate (14) to the bottom of the push frame. Butt one edge of the plate against the new bottom assembly and locate the other edge as shown in the illustration. Tack weld plate (14) to the bottom of the push frame.
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| Illustration 53 | g03653363 |
- Finish weld the top side of plate (14) of the push frame to bottom assembly (1) using a 6 mm (0.24 inch) flare bevel groove weld. Weld the plate on two edges.
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| Illustration 54 | g03653393 |
Left side of the machine View of the top side of the push frame | |
- Finish weld plate (14) from location (N) to (P) using a 5 mm (0.2 inch) fillet welds.
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| Illustration 55 | g03653397 |
View of the bottom side of the push frame. | |
- On the left side push frame tack on the following parts in the specified order. Tack on plate (6), plate (15), plate (9), plate (11), and plate (7) .
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| Illustration 56 | g03653405 |
The left side push frame | |
- The right side push frame is not shown but is a mirror image of the figure above. On the right side push frame tack on the following parts in the specified order. Tack on plate (4), plate (15), plate (4), plate (5), plate (8), and plate (10) .
- Weld out the push frame parts. Weld paths in red that are marked with (R) using a 6 mm (0.24 inch) fillet/groove. The weld paths in black are marked with an (S) using a 5 mm (0.2 inch) fillet/groove.
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| Illustration 57 | g03653411 |
- Weld in gusset (12), and gusset (13). Maintain a distance of dimension (T) for plate (12). Align and tack both plate (12) and gusset (13) in the appropriate position, gauging from the way the gussets align to each other.
Note: Do not weld corners (W)
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| Illustration 58 | g03653414 |
(T) 59 mm (2.3 inch) | |
- Seam (T) is welded using a 6 mm (0.24 inch) fillet weld.
- Seam (U) is welded using a 6 mm (0.24 inch) groove weld.
- Seam (V) is welded using a 10 mm (0.39 inch) groove weld.
- Do not weld corners (W) .
- Seams (X) is welded using a 6 mm (0.24 inch) fillet welds.
- Remove all bracing from the bowl and push frame sides.
- Repair any gouges from removing the bracing.
- If liner plates are installed back in place, do not weld the liner plates onto the bowl sides so that they are positioned closely to the front of the floor, close to where the cutting edges mount. This ensures that the new floor structure will perform as intended.
Assembly
- Install the ejector and apron back onto the machine. Also install the cutting edges. Check and adjust all ejector rollers as per the Operation and Maintenance Manual. Perform this procedure before the ejector is moved and the machine is put back into service. The ejector needs to have the proper clearance with the surroundings or interference and damage may occur.