- Dragline
- DRAGLINES - LEGACY (S/N: BP31-UP)
Introduction
This Special Instruction provides the instruction to support the field assembly of dragline buckets. The size of the bucket is
The dragline bucket can be field welded and assembled at any time during machine installation, and at any convenient location on the site.
The bucket is partially fabricated and fit-up in the factory prior to shipment to the installation site. The bucket is then disassembled for shipment. Alignment bolts and rods are provided to ensure proper fit-up in the field.
The bucket side and bottom plate assemblies, lip, and arch are shipped to the field separately and must be fit-up and welded.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
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 must 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 of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Operation of the machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the warnings are understood.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage. |
Personal injury or death can occur from not following the proper procedure or the recommended tooling. To prevent the possibility of injury or death, follow the established procedure using the recommended tooling. |
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. |
Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
Welding Requirements
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 by reading and understanding 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 instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See “American National Standard Z49.1, Safety in Welding and Cutting” which is published by the American Welding Society. American Welding Society8669 NW 36 Street #130 Miami, Florida 33166-6672 1-800-443-9353 See “OSHA Safety and Health Standards, 29 CFR 1910” which is available from the U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 See applicable requirements for your local area. |
Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.
Refer to the Illustrations in this Special Instruction for welding symbols and specifications.
All electrodes must be dried. The electrodes can be dried by heating the electrodes to
Do not weld in windy conditions. Do not weld when temperatures are below
Penetration characteristics may vary greatly depending on the following conditions:
- Electrode diameter
- Shielding gas
- Welding current
- Plate thickness
The following items also affect the welds:
- Geometry of welded joints
- Surface conditions
- Composition of the base metal and of the electrode
A root pass should be applied before each weld is finished.
Maintain a
For more information, refer to Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide".
Preparing the Surfaces for Welding
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. |
All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.
Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.
Note: After welding, allow all areas to cool to room temperature. After the areas have cooled, paint the area with primer. After the primer has dried, coat the area with Cat 4C-4200 Yellow Paint.
NOTICE |
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Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
Reference Section
Special Instruction, REHS1841, "General Welding Procedures"
Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide"
Installation Procedure
- Using a crane, position the two side and bottom plate assemblies on blocks. Align the top holes in the bottom plates.
Blocks should be high enough at the front to allow installation of tooth points after bucket is welded. The bottom plates should be level in both direction.
- Install the alignment bars and bolts furnished with the bucket. Three bolts in the bottom and three bolts at the rear of the bucket.
Align the two side and bottom plate assemblies. Brace the sides and back of the bucket after bolts are installed.
- Using a crane, position the lip and clevis plate assembly on the front of the bucket.
Align the assembly with the side and bottom plate assemblies. Install the alignment bolts and nuts.
- Position the arch on the clevis plate and fully align the arch to the clevis plates. Move the side plate assemblies if needed to align the arch properly.
- Tack weld the arch securely to the clevis plates at several locations. Weld the arch to the clevis plates using procedures in Appendix Manual.
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Illustration 1 g06082224 (B) is 456.0 ± 10.0 mm (17.95 ± 0.39 inch)
(C) is88.0 ± 10.0 mm (3.46 ± 0.39 inch) at two places
(N) is2556.0 ± 10.0 mm (100.63 ± 0.39 inch)
(P) is2443.0 ± 10.0 mm (96.18 ± 0.39 inch) at two places
(S) is center of gravity
(W1)36.0 mm (1.42 inch) bevel weld and34.0 mm (1.34 inch) bevel weld on the other side
(W2)48.0 mm (1.89 inch) bevel weld
(W3)36.0 mm (1.42 inch) fillet weld on both sides from location (D) to location (G)
( W4)8.0 mm (0.31 inch) fillet weld on both sides from location (G) to location (H)
( W5)30.0 mm (1.18 inch) bevel weld on other side from location (F) to location (L)
( W6)6.0 mm (0.24 inch) all around fillet weld
(W7)8.0 mm (0.31 inch) X12.0 mm (0.47 inch) fillet weld from location (H) to location (J)Show/hide tableIllustration 2 g06082234 View of area K
(T)10.0 mm (0.39 inch)
(W8)3.0 mm (0.12 inch) fillet weld
(U) No weld permitted in this areaShow/hide tableIllustration 3 g06082272 View A-A
(W9)18.0 mm (0.71 inch) V-groove weld from location (V) to location (X)
( W10)38.0 mm (1.50 inch) V-groove weld from location (X) to location (Y). Refer below Illustration for location (Y)Show/hide tableIllustration 4 g06082300 View R-R
(S) is center of gravity
(Y)2856.0 mm (112.44 inch)
(Z)507.3 mm (19.97 inch)
(AB)228.6 ± 2.0 mm (9.00 ± 0.08 inch)
(AC)203.2 ± 2.0 mm (8.00 ± 0.08 inch) at six places
(AD)570.0 ± 2.0 mm (22.44 ± 0.08 inch)
(AE)925.6 ± 2.0 mm (36.44 ± 0.08 inch)
(AF)1281.2 ± 2.0 mm (50.44 ± 0.08 inch)
(AG)1636.8 ± 2.0 mm (64.44 ± 0.08 inch)
(AH)1992.4 ± 2.0 mm (78.44 ± 0.08 inch)
(AJ)2348.0 ± 2.0 mm (92.44 ± 0.08 inch)
(AK)2703.6 ± 2.0 mm (106.44 ± 0.08 inch)
(W11)18.0 mm (0.71 inch) bevel weld from location (M) to location (AA)
( W12)18.0 mm (0.71 inch) all around fillet weld
(W13) Combination of12.0 mm (0.47 inch) bevel weld and18.0 mm (0.71 inch) fillet weldShow/hide tableIllustration 5 g06082362 (S) is center of gravity
(AN)101.6 ± 2.0 mm (4.00 ± 0.08 inch)
(AU)1124.3 mm (44.26 inch)
(W14)14.0 mm (0.55 inch) fillet weld from location (AP) to location (AS) and from location (AT) to location (AR)
( W15) Combination of2.0 mm (0.08 inch) square weld and18.0 mm (0.71 inch) V-groove weld
(W16)20.0 mm (0.79 inch) bevel weld from location (AV) to location (AX)
( W17)18.0 mm (0.71 inch) bevel weld from location (AP) to location (AR)Show/hide tableIllustration 6 g06082386 View of AL-AL
(AY)2397.0 to 2399.0 mm (94.37 to 94.45 inch) at two places
(AZ)2193.6 to 2195.6 mm (86.36 to 86.44 inch) at two places
(BA)440.6 ± 2.0 mm (17.35 ± 0.08 inch) at two places
(BB)76.2 ± 2.0 mm (3.00 ± 0.08 inch) - Securely tack weld the lip to the bottom plates and the clevis plates to the side plates. Also securely tack weld the side plates to each other at the back and at the bottom.
- Starting at the center of the lip, weld the lip to the bottom plate, working towards the side plate joint. Use two welders, one working in each direction. Refer to Illustration 1, Illustration 2, Illustration3, Illustration4, Illustration 5, and Illustration 6 for welding dimensions.
Note: Refer to the appropriate bucket drawing for weld sizes and locations. Also refer to Topic"Run-off Tabs" for correct use of run-off tabs and Topic "Weld Grinding" for weld grinding instructions.
- Weld side plates to the clevis plates and vertical portion of the lip. Again use a team of welders. Work from the bottom of the bucket towards the top. Apply the inside welds first then the welds outside the bucket
- Weld the center joint between the side and bottom plate assemblies. Work from the bottom towards the top at the rear of the bucket and from the front towards the rear on the joint
- Remove the alignment bolts, bars, and pins.
- Install the reinforcing bar on the inside of the bucket over the side and bottom plate assembly joint and weld in place.
- Roll the bucket over to gain access to the bottom surface of the bucket. Apply fillet weld to the center reinforcing bar to the center reinforcing bars at the joint between the side and bottom plate assemblies.
The joint involves two bars running from the top rear of the bucket to the lip. Install any skid plates which were shipped loose.
- With the bucket rolled plug weld the accessible alignment holes. Reposition the bucket in the position and plug weld the remaining alignment holes.
Note: All plug welds are to be flush with the inside surface of the bucket.
- Check all weld joints against the engineering drawing to make sure that all welds have been completed.
- Install tooth point adapters on the bucket lip and secure with the thimbles and wedges. Trim the wedges flush with the bottom of the tooth and approximately two inches above the tooth after the wedge is driven in place.
- Install the replaceable tooth points and secure with pins and rings.
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Illustration 7 g06070264 (E) Hoist rope
(F) Dump block links
(G) Pickup link
(H) Dump block
(J) Hoist clevis
(K) Dump rope
(L) Anchor and equalizer link
(M) Dump clevis
(N) Trunnion link
(P) Dump chain
(R) Dump clevis
(S) Drag ropes
(T) Drag link
(U) Drag clevis
(V) Drag chain
(X) Drag clevis
(Y) Trunnion pin
(Z) Bucket - Install the trunnion links and secure with trunnion pins as shown in Illustration 7. Install the trunnion pin retaining bolt and nut. Upset the threads of the retaining bolt to keep the nut from loosening.
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Illustration 8 g06070311 (AA) Hoist equalizer
(AB) Equalizer link
(AC) pickup link
(AD) Hoist clevis
(AE) Upper hoist chain
(AF) Spreader
(AG) Lower hoist chain
(AH) Trunnion links - Assemble the hoist equalizer, equalizer link, pickup link, and hoist clevis as shown in Illustration 8.
Install the pins with lubrication fittings so the lubrication holes are on the loaded side of the pin. Weld the pin retainers to the links with bevel welds.
- Attach the upper and lower hoist chains to the spreader with pins. Refer to Illustration.
Weld the pin retainers to the spreader with a bevel weld. Attach the equalizer and link assembly to the upper chains. Weld the pin retainers. Attach the ends of the lower chains to the trunnion links on the bucket. Secure with pins and weld the retainers to the trunnion links.
- Lay the drag chains out in front of the bucket as shown in Illustration. Assemble the drag clevis to each end of each drag Chain.
Install the clevises at the bucket end on the bucket and pin to the clevis plates. Weld pin retainers to the clevis plates.
- Attach the right and left-hand drag links.
Run-off Tabs
Illustration 9 | g06082434 |
Correct use of run-off tabs |
Illustration 10 | g06082438 |
Incorrect use of run-off tabs |
Run-off tabs are used at edges of weldments to improve the weld class. The tabs continue the groove beyond the part. As the groove is being welded, the starts or stops will end in the run off tab area. Refer to Illustration9 and Illustration 10 for correct use of run-off tabs.
Illustration 11 | g06082447 |
The run-off tabs are then removed by cutting off the tabs with a torch. Ground flushes the surface with the plate surface. Prevent concave grinding of the weld as shown in Illustration 11.
When adding weld tabs, tack tabs inside the weld groove. The tabs are
Grinding Weld-Ends
Illustration 12 | g06082474 |
Illustration 13 | g06082487 |
(1) Location of grinding weld-ends (2) Location of grinding weld-crossing |
Illustration 14 | g06082499 |
Before grinding at weld-ends |
Illustration 15 | g06082503 |
After smooth grinding at weld-ends |
- Use polishing tool to smoothly grind the weld ends from location (A) to location (B) and from location (C) to location (D)
- Maintain minimum roughness of
0.40 mm (0.016 inch) - Maintain minimum radius of
3.0 mm (0.12 inch) - Concave grinding not permitted.
Grinding Weld-Crossing
Illustration 16 | g06082523 |
View of area F (2) Location of grinding weld-crossing |
- Flush grind of weld 1 before grinding of weld 2. Root of weld 2 needs to be clean as shown in Illustration 16.