Spill Guard Installation Procedure for Certain Buckets on R2900G Load Haul Dump Machines{7186} Caterpillar


Spill Guard Installation Procedure for Certain Buckets on R2900G Load Haul Dump Machines{7186}

Usage:

R2900G GLK
Load Haul Dump:
R2900G (S/N: GLK1-UP; JLK1-UP)

Introduction

This special instruction covers the installation procedure of the bucket spill guard for 248-4899 Bucket , 249-4915 Bucket , 249-4892 Bucket , 249-4916 Bucket , 249-4893 Bucket and 249-4914 Bucket . 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.

ReferenceDisassembly and Assembly, RENR7819, "Steering Frame Lock - Separate and Connect" for the machine being serviced.

ReferenceDisassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install" for the machine being serviced.

ReferenceService Manual, RENR8594, "Machining and Welding Information for Load Haul Dumps".

Safety Section

------ WARNING! ------

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
----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

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 in order 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.

Installation Procedure

Table 1
Parts Required    
QTY     Part Number     Description    
1     270-5409     Guard Gp - Overflow    
1     270-5402 (1)     Bar - Spill Guard    
4     270-5403 (1)     Plate    
1     270-5404 (1)     Shroud - Spill Guard    
( 1 ) Part not serviced separately.

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

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

  1. Lower the bucket to the ground and apply a slight downward pressure.

  1. Stop the engine.

  1. Connect or install the steering frame lock. Refer to Disassembly and Assembly for the machine being serviced.

  1. Turn the disconnect switch to the OFF position.



    Illustration 1g02565296

    (1) Bucket leveling gauge

  1. Remove bucket leveling gauge (1). Retain for installation purposes.

    Note: Check the position of leveling gauge (1) prior to removing. Refer to Illustration 2 to determine if the leveling gauge needs repositioning.




    Illustration 2g02562744

    (A) 158 mm (6.22 inch)

    (B) 135 mm (5.31 inch)

    (W1) 12 mm (0.47 inch)

  1. Position bucket leveling gauge (1) removed in Step 7.

  1. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

  1. Weld bucket leveling gauge (1) to the bucket.



    Illustration 3g02562777

    (2) 270-5402 Bar - Spill Guard

    (3) 270-5403 Plate

    (4) 270-5404 Shroud - Spill Guard

    (C) Refer to Table 2

    (D) 76 mm (2.99 inch)

  1. Position and tack weld four 270-5403 Plates (3), 270-5404 Shroud - Spill Guard (4) and 270-5402 Bar - Spill Guard (2) to the bucket. Refer to Illustration 3 and Table 2.

    Table 2
    Bucket Part Number     (C)    
    249-4899    
    159 mm (6.26 inch)    
    249-4915    
    159 mm (6.26 inch)    
    249-4892    
    209 mm (8.23 inch)    
    249-4916    
    209 mm (8.23 inch)    
    249-4893    
    309 mm (12.16 inch)    
    249-4914    
    309 mm (12.16 inch)    



    Illustration 4g02565298

    (2) 270-5402 Bar - Spill Guard

    (3) 270-5403 Plates

    (4) 270-5404 Shroud - Spill Guard

    (W2) 12 mm (0.47 inch)

    (W3) 12 mm (0.47 inch)

    (W4) 12 mm (0.47 inch)

  1. Pre-heat the areas to be welded.

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Preheat, Interpass, and Heat Input".

    ReferenceRefer to Service Manual, Machining, and Welding Information for Load Haul Dumps, "Consumables".

  1. Weld 270-5402 Bar - Spill Guard (2), four 270-5403 Plates (3), and 270-5404 Shroud - Spill Guard (4) to the bucket.

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