Procedure to Rework the Bucket Stops on R3000H Load Haul Dump Machines {6101} Caterpillar

Load Haul Dump

R3000H (S/N: RCM1-UP; RCY1-127)

Introduction

This special instruction covers the procedure to rework the bucket stops on the above Load Haul Dump Machines. 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 Section

Reference: Service Manual, RENR8594, "Machining and Welding Information for Load Haul Dumps".

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

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

Machine Preparation

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Procedure

Two procedures are available. Assess whether the stops are to be repaired or replaced.

Note: For welding repairs performed on Caterpillar Underground machines using Manual Metal Arc Welding (MMAW), use AWS E7016 electrodes for the first three passes. Use AWS E7018 electrodes for the remaining passes of the welding repair.

Note: For all welding repairs performed on Caterpillar Underground machines using Gas Metal Arc Welding (GMAW) use AWS ER70S-6 wire.

Repair Procedure

1. Preheat the repair area prior to arc air gouging. Refer to Service Manual, "Preheat, Interpass, and Heat Input" for the correct temperatures.
   Show/hide table

   Illustration 1	g06019300
   (1) Plate (2) Plate

2. Thoroughly remove all cracks from around plate (1) and plate (2).
   Show/hide table

   Illustration 2	g06019304
   (1) Plate (3) Plate (A) Chamfer 18 mm (0.70 inch)

3. Grind two chamfers (A) on plate (1).

   Note: Do not grind the weld on plate (3).

4. Thoroughly grind clean the repair area, remove all scale and carbon. Thoroughly clean the repair area. Remove any paint and grease which may remain in the repair area.

5. Preheat the weld area prior to welding. Refer to Service Manual, "Preheat, Interpass, and Heat Input" for the correct temperatures.

6. Fill with weld, areas where cracks were removed. Refer to Step 2.
   Show/hide table

   Illustration 3	g06019307
   (1) Plate

   Show/hide table

   Illustration 4	g06019324
   (1) Plate (4) Blended weld (B) Radius 40 mm (1.60 inch)

7. Weld plate (1). Refer to Illustration 3, Illustration 4, and Table 1.

   Note: Ensure a seamless blended weld in four places (4). Refer to Illustration 4.

   Show/hide table

   Table 1

   Item	Description
   W1	20 mm (0.80 inch) Groove weld
   W2	20 mm (0.80 inch) Fillet weld with 3 mm (0.12 inch) root penetration

8. If cracks were removed from around plate (2), weld plate (2). Refer to Illustration 11 and Table 3.

9. Using a suitable thermal covering, cover the repaired area to regulate the cooling of the area.

Rework Procedure

Plate Manufacture

Use "Bisalloy 600/700" with 620 mpa minimum yield or equivalent, to manufacture the following plates.

Show/hide table

Illustration 5	g06019320
(1) Plate (A) Chamfer 18 mm (0.70 inch) (B) 360 mm (14.25 inch) (C) 285 mm (11.25 inch) (D) 5 mm (0.20 inch) (E) 20 mm (0.80 inch)

1. Manufacture two plates (1).
   Show/hide table

   Illustration 6	g06019660
   (2) Plate (F) Radius 20 mm (0.80 inch) (G) 130 mm (5.125 inch) (H) Radius 10 mm (0.40 inch) (J) 132 mm (5.25 inch) (K) 100 mm (4.0 inch) (L) 25 mm (1.0 inch) (M) 10 mm (0.40 inch) (N) 260 mm (10.25 inch)

2. Manufacture two plates (2).

Rework

1. Preheat the repair area prior to arc air gouging. Refer to Service Manual, "Preheat, Interpass, and Heat Input" for the correct temperatures.
   Show/hide table

   Illustration 7	g06019662

2. Remove and discard two plates (3) and two plates (4).

3. Check for cracking around the rework area, repair as required.

4. Thoroughly grind clean the rework area, remove all scale and carbon. Thoroughly clean the rework area. Remove any paint and grease which may remain in the rework area.

   Note: The new plates must sit flat, ensure that no high points or low points are visible.

5. Preheat the weld area prior to welding. Refer to Service Manual, "Preheat, Interpass, and Heat Input" for the correct temperatures.
   Show/hide table

   Illustration 8	g06019676
   (1) Plate (A) 370 mm (14.50 inch) (B) 15 mm (0.60 inch)

   Show/hide table

   Illustration 9	g06019683
   (1) Plate

   Show/hide table

   Illustration 10	g06019687
   (1) Plate (5) Blended weld (C) Radius 40 mm (1.60 inch)

6. Weld in position two plates (1) that were manufactured in "Plate Manufacture", Step 1. Refer to Illustration 8 through Illustration 10 and Table 2.

   Note: Ensure a seamless blended weld in four places (5). Refer to Illustration 10.

   Show/hide table

   Table 2

   Item	Description
   W1	20 mm (0.80 inch) Groove weld
   W2	20 mm (0.80 inch) Fillet weld with 3 mm (0.12 inch) root penetration

7. Preheat the weld area prior to welding. Refer to Service Manual, "Preheat, Interpass, and Heat Input" for the correct temperatures.
   Show/hide table

   Illustration 11	g06019697
   (2) Plate (D) 47 mm (1.85 inch) (E) 50 mm (2.0inch)

8. Weld in position two plates (2) that were manufactured in "Plate Manufacture", Step 2. Refer to Illustration 11 and Table 3.
   Show/hide table

   Table 3

   Item	Description
   W3	20 mm (0.80 inch) Fillet weld all around with 3 mm (0.12 inch) root penetration

9. Using a suitable thermal covering, cover the reworked area to regulate the cooling of the area.