Manual Dipper 7495 - Inspeccion en Campo OEM PDF

18/5/2018 USE PARTS IDENTIFICATION EXPANDED MINING ER600001-UP (MACHINE)(SEBP6510 - 00) - Sistemas y componentes
Pantalla anterior
Bienvenido: r080jvq
Producto: ELECTRIC ROPE SHOVEL
Modelo: 7495 ELECTRIC ROPE SHOVEL ER601508
Configuración: USE PARTS IDENTIFICATION EXPANDED MINING ER600001-
UP (MACHINE)
Pautas de reutilización y recuperación

Electric Rope Shovel Dipper Inspection Reuse & Salvage{0374, 0599, 6514, 7000}
Número de medio -SEBF9386-00 Fecha de publicación -17/07/2015 Fecha de actualización -17/07/2015
Caterpillar: Confidential Yellow
i06052651
Electric Rope Shovel Dipper Inspection Reuse & Salvage{0374, 0599,

6514, 7000}
SMCS - 0374; 0599; 6514; 7000
Electric Rope Shovel:

7182 (S/N: ER21-UP)
7295 (S/N: ER31-UP)
7295 HD (S/N: ER41-UP)
7395 (S/N: ER51-UP)
7495 (S/N: ER61-UP)
7495 HD (S/N: ER71-UP)
7495 HF (S/N: ER81-UP)
Introduction
Table 1
Revision Summary of Changes in SEBF9386
© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of
this document or the proprietary processes therein without permission may be violation of intellectual property
law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts
reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost
reductions. Every effort has been made to provide the most current information that is known to Caterpillar.
Continuing improvement and advancement of product design might have caused changes to your product which
are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical
information that is available from Caterpillar.
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For questions or additional information concerning this guideline, submit a form for feedback in the Service
Information System. To address an urgent issue, use the following resources to communicate your request to
Caterpillar Repair Process Engineering:
Caterpillar Dealer Technical Communicator
Dealer Solution Network
Caterpillar Technical Representative
Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information
about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced
parts.
Note: This procedure can be used for various Dipper Part Numbers. Orders for related parts are to be placed
through ANTARES with Part Type "BE". The orders will be processed through the Dealer Parts Service Center
(DPSC).
Summary
Illustration 1 g03797249
Example of 7495 Dipper
This guideline provides the procedures that are necessary to inspect and determine the reusability for the Electric
Rope Shovel Dippers. This guideline explains the procedure for inspecting and measuring individual
components.
This guideline contains the latest standards of engineering, which will help minimize owning and operating
costs. A part can be expected to reach the next Planned Component Repair if the part meets the specifications in
this guideline assuming the part is used in the same application. Use this guideline in order to determine whether
a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition
that might have caused the original failure.
Important Safety Information
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. If a tool, a procedure, a work method, or operating technique that is not recommended by
Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be
damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair
procedures that are used.
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as r080jvq
"DANGER", "WARNING" or "CAUTION". Refer to Illustration 3for an example of Caterpillar:
a "WARNING" SafetyYellow
Confidential
Alert Symbol.
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this
publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
safety information in this document and the safety information on the machine are not all inclusive.
Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that
the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also,
determine that the operation, lubrication, maintenance, and repair procedures will not make the machine
unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information
which was available at the time of publication. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service that is
given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers
can supply the most current information.
References
Use the following references for additional information regarding the rebuild of a Dipper.
Table 2
References
SEBD0512 Caterpillar Service Welding Guide
SEBF8187 Standardized Parts Marking Procedures
SEBF9331 7495 Padlock Reuse Inspection Procedure
- Disassembly, Inspection & Rebuild of Link Assembly
- Electric Roper Shovel Service Manual
Service Advisories
NOTICE
The most recent Service Advisories related to this component should be
reviewed before beginning work. Often service advisories contain
upgrades in parts and safety information.
Service Intervals
Service intervals vary widely between different mine sites due to different applications and severity. Each region
or location should develop their own service interval for Dippers. Intervals should be based on past experience
and data obtained from performing daily TA-1 inspections and preventative maintenance checks.
NOTICE
It is recommended that at the minimum a dipper shall have a Level 1
rebuild performed at least once per year based on the hours
accumulated as shown in Table 3.
Table 3
General Minimum Recommended Service Information
Rebuild Level Hours (1)
1 6,000 (2)
(1) Assume a mean average of 6,000 hours per year.
(2) May require rebuild at less than recommended hours if more severe conditions or applications exist.
Note: If a dipper is inspected and maintained regularly and does not experience abnormal or severe conditions it
can be expected to last for seven rebuilds.
Welder Qualifications
Welders must be qualified for the appropriate type of weld that is being performed. Shielded Metal Arc Welding
(SMAW) or Flux Cored Arc Welding (FCAW). Qualifications should be in accordance with ANSI/AWS D1.1,
D14.3, or Caterpillar Manufacturing Practice MC1000-105. Welders must be qualified for the appropriate
position of weld that is being performed. Refer to AWS Specifications D1.1 and D14.3 or comparable standards
for information that regards qualification requirements. The welders must have used the process at some time
within the last 6 months. The welders must complete the process of certification if the welders have not used the
welding processes for 6 months. The welding operator must hold a current certification for this process.
Tooling & Equipment

Table 4
Required Tooling and Equipment
Part Number Description Qty
420-5317 Suitable Cribbing (1)
5P-3920 Rule- Steel 1

385-8484 Level 1
5P-1720 Seal Pick 1
9U-7377 Metal Marking Pen 1

263-7184 Crack Detection Kit 1
4C-4805 Developer (1)
399-5769 Whisler 12 Shroud Gauge 1 (2)

450-1642 Whisler 10 Shroud Gauge 1 (3)
399-5770 Whisler 12 Adapter Gauge (2)
450-1641 Whisler 10 Adapter Gauge (3)
457-1628 Upper Corner Gauge (1)
457-1629 Lower Corner Gauge (1)
385-4008 Micrometer Tool Set, External 1

385-9422 Micrometer Tool Set, Internal 1
222-3071 Angle Die Grinder (1)
222-3074 Medium Mini Die Grinder (1)
222-3076 Right Angle Die Grinder (1)
222-3077 Extended Die Grinder (1)
222-3080 Long Air Hammer (1)
223-4356 Weld Breaker (1)
236-8097 Carbide Burr (1)
1U-6825 A-Shaped Grinding Wheel (1)
4C-3770 Grinding Wheels (1)
254-5342 Flap Disc (1)
254-5319 Surface Condition Brush (1)
415-4055 Ultrasonic Tool GP (1)
349-4203 Infrared Thermometer (1)
4C-4113 Oxy - Propane Kit (1)
4C-5823 Heating Torch Handle (1)
4C-5830 Heating Torch Mixer (1)
4C-5831 Tip Tube (1)
4C-9616 Welding Blanket (1)
477-3166 (4) Portable Boring Bar (110V) (1)
477-3167 (4) Portable Boring Bar (240V) (1)
477-3189 Bore Welding System (1)
- Welding, Cutting, & Arc Gouging Equipment (1)
- Welding Electrodes/Filler Metals (5)
- Straight Edge (1)
- Temperature Indicating Crayon (1)
(1) As needed.
(2) Required for Dippers with Whisler 12 Lips
(3) Required for Dippers with Whisler 10 Lips
(4) Various bar lengths and additional tooling is available through Dealer Service Tools.
(5) Refer to the ""Filler Metals" " section of this document.
Measurement Techniques
Example of measuring bore Inside Diameter (ID) of padlock bore
(D) Indicates the diameter of the bore.
(T) The overall width or thickness of bore.
Take measurements at locations (D1), (D2), and (D3).
Then take measurements at locations (D4), (D5), and (D6).
Typical example of measuring Outside Diameter (OD) Dimension.
(A) Example padlock pin
(B) Straight edge
Note: Measurements taken on the edge of a part may give an inaccurate measurement.
(E) Indicates the diameter of the shaft.
Take measurements at locations (E1), (E2), and (E3) .
Then take measurements at locations (E4), (E5), (E6) at distances (G) which are equal to (25%) x (F) .
Ensure that several sample measurements are taken at different locations (G) on the same feature. Measure
diameters of internal bores and external shafts in a minimum of six places to identify tapered and or oval
conditions. Refer to Illustrations 4 and 5.
Using a straight edge (B) check for distortion along pin length. If gaps (H) are found it may indicate pin is
distorted. Contact the Dealer Solutions Network (DSN) if these conditions exist.
Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four
decimal places in inches or three decimal places in millimeters. Measuring tools should be calibrated using gage
blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).
Preparation Recommendations
P li j lt h i l l t
Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and warnings on

the cleaner solvent container before using.
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.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
Note: Before inspection the following is suggested
Entire dipper should be steam cleaned and the weld joints sand blasted to remove all paint, grease, oil,
dirt, and scale.
Clean individual parts to be inspected thoroughly to ensure that parts are free from debris prior to
inspection.
Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent
damage to the part when you lift the part.
During cleaning, do not damage machined surfaces.
Use pressurized air to dry parts.
Put gear oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately
after cleaning. Carefully store the parts in a clean container.
Use appropriate thread taps to chase all threaded holes.
Dipper Configurations and Terms

Caterpillar dippers have been optimized over the years to ensure a balance between the height, width, and depth
to achieve effective dipper fill levels. Each dipper is carefully sized based on specific mine conditions and
factors such as material densities, working conditions, and haulage systems. The sections that follow explain the
general dipper configurations available and component nomenclature.
Dipper Body Styles
Example of FastFill (Trapezoidal) body style
Example of Straight-Sided body style
Two different body styles are available: The FastFillTM (Trapezoidal) & Straight-Sided. The FastFillTM
trapezoidal shape is designed to eliminate the void that occurs in the dipper at the upper corners. The box shape
of the Straight Sided body style is designed to accommodate larger dipper volumes.
Dipper Lips
Example of dipper lip styles
(R) Standard Spade Lip (Round Bottom)
(F) Straight Flat Lip (Flat Bottom)
Standard Spade Lips (R) with round bottoms provide easier penetration into bank, lower bank resistance,
reduced corner loading, and reduced drag. Straight Flat Lips (F) with flat bottoms are more commonly used in
iron ore applications where a better fill is obtained with more blocky materials.
Latched & LatchFreeTM
Latched (Top) VS. LatchFreeTM
(A) Latch Bar
(B) LatchFreeTM Assembly
Dipper doors can open and close by two mechanisms. The traditional mechanism uses a latch bar (A) which
slides out the bottom of the dipper door into a latch keeper located in the dipper bowl. The LatchFree TM design
(B) uses an arm assembly which rotates a cam which releases the link structure attached to the back of the door.
Dipper Liners
Liners are the hardened high carbon steel wear plates which cover specific areas of the dipper body and dipper
door. There are various configurations depending on the applications as outlined in the following sections.
Standard Liner Package
Medium Abrasiveness/Medium Impact Package
This package is used in a broad range of applications including coal, copper, diamond, gold, molybdenum,
phosphates, potash, and fertilizers among others. Liner thickness range between 12.7 mm (0.50 inch) to 19.05
mm (0.75 inch).
Other Liner Packages
High Abrasive/Low Impact Package
This liner is typically used in oil sands applications using a liner thickness of 12.7 mm (0.50 inch).
High Abrasive/High Impact Package
This liner package is used in iron ore applications using thick liners ranging from 25.4 mm (1.0 inch) to 50.8
mm (2.0 inch).
Major Dipper Components & Nomenclature
(A) Snubber
(B) Adjustable Pitch Brace
(C) Padlock
(D) Ground Engaging Tools (GET)
(E) Liners
(F) Heel Bands
(G) Door Liners
(H) Door
(J) Latch Keeper
(K) Latch Bar
(L) Dipper Back
(M) Side Plates
(N) Dipper Bowl Castings
(P) Dipper Lip
(R) Front Castings
(T) Shroud
(U) Tooth
(V) Adapter
(W) Lip
(X) Wedge
(Y) C-Clamp
(Z) Serial Number Plate
Note: Traditional C-Clamp & Wedge type GET shown in location (D) of Illustration 10. Various GET
configurations, including hammerless designs, are available depending on dipper applications.
Inspection
Documentation During Repair & Salvage
Dipper Body Crack Map
Dipper Door Crack Map
It is suggested that during all inspections for the dipper body and dipper door a crack map similar to the maps
shown in Illustrations 11 and 12 are used to document any findings.
Refer to the ""Crack Detection Methods" " section of this document for non-destructive inspection methods.
During inspection indicate on the crack maps the location and lengths of cracks found. Each area should also be
marked on the actual part using a metal marking pen so that the welder knows where to excavate.
Repair Costs & Estimating
(A) Surface indications - 102 mm (4.0 inch)
(B) Final excavation - 432 mm (17.0 inch)
During inspection of the dipper it may be necessary to estimate the time or cost of repair. Overall dipper repair
costs are affected by application, operating conditions, ownership period, maintenance, and age of the
equipment. A significant factor of the repair cost is whether the repair is performed before or after catastrophic
failure. Repair before a major component failure can be one-third of an after failure repair with only a moderate
sacrifice in life. Therefore maintenance practices are a significant factor because they affect component
longevity and the percentage of scheduled, before failure repairs.
Note: It is difficult to estimate the repair time and cost of cracks without knowing how deep or far the cracks
will travel during excavation by air carbon arc gouging. A crack that only appears to be a few inches at the
surface may end up being several inches longer and through the full thickness of the material. This will
significantly increase the repair time and cost. Therefore it is encouraged that the following minimum steps are
taken to ensure that all work is documented. Refer to Illustration 13 as an example.
1. Remove crack as outlined in the ""Crack Repair" " section of this document.
2. When the entire crack has been excavated, verify removal using one of the methods in the ""Crack
Detection Methods" " of this document.
3. Document final depth and length of excavation by taking a photo showing removal verification from step
2.
4. When preheat is required before air carbon arc gouging or welding use an infrared thermometer or
temperature indicating crayon and document with photos. Use a temperature control chart as shown in
Illustration 14 in order to show constant monitoring of preheat and interpass temperatures.
5. If any stress relieving or slow cooling is performed document with chart recorder or photos.
Example of temperature control chart
(A) Date and relevant part information
(B) Use of infrared thermometer or temperature indicating crayon
(C) Temperatures on indicating crayons
(D) Calibration date of infrared thermometer

(E) Actual temperature found during repair
(F) Photos showing preheating
(G) Photos showing preheat temperature verification using temperature indicating crayon
Inspection Priority and Order
(1) Teeth, Shrouds, & Adapters
(2) Liners
(3) Lip
(4) Leading Edge
(5) Dipper Back & Front Rear Edge
(6) Latch Keeper
(7) Padlock Lugs/Bores
(8) Door Hinge Lugs/Bores
(9) Bowl/Front Castings
(10) Heel Bands
(11) Handle Lugs/Bores
(12) Pitch Brace Lugs
(13) Side Plates
(14) Liners
(15) Bottom of Door
(16) Thickness Transition
(17) Latch Bar & Arm
(18) Vertical Welds
(19) Door Hinge Lugs/Bores
Table 5
Dipper Body
Priority Location Description
1 1 Teeth, Shrouds, & Adapters
2 2 Liners
3 10 Heel Bands
4 3 Lip
5 4 Leading Edge
6 5 Dipper Back & Front Rear Edge
7 6 Latch Keeper
8 7 Padlock Lugs/Bores on Dipper
9 8 Door Hinge Lugs/Bores
10 9 Bowl/Front Castings
11 11 Handle Lugs/Bores
12 12 Pitch Brace Lugs
13 13 Side Plates
Table 6
Dipper Door
Priority Location Description
1 14 Liners
2 15 Bottom of Door
3 16 Thickness Transition
4 17 Latch Bar & Arm
5 18 Vertical Welds
6 19 Door Hinge Lugs/Bores
It is suggested that first a general overall visual inspection of the dipper with door is performed in order to see if
any major or obvious damages are present. This may include damages from situations where the door or body
has come into contact with a truck body. This may cause the door to bend or twist and not close properly and
will determine if the dipper or door should be immediately removed and taken to a dedicated repair shop.
Once it is determined that there are no major or obvious damages, a more detailed inspection based on the
highest impact areas can be performed. Illustration 15 and Tables 5 and 6 are some general guidelines indicating
which high wear areas or damages may occur. The inspection priority for each dipper is best determined based
on the past experience of the mine site or data obtained from TA-1 inspections.
Specific inspection requirements, measurements, and salvage techniques for each area of the dipper and door can
be found in the ""Inspection & Salvage By Component" " section of this document.
(A) Padlock bore with abnormal and excessive wear.
(B) Crack in Dipper Door propagating to middle of plate.
NOTICE
If excessive or abnormal damages or wear is encountered as shown in
Illustration 16 contact the Dealers Solution Network (DSN) for specific
instructions.
Areas underneath liner plates (C)
During a complete Level 1 rebuild the GET components (Dipper Teeth, Shrouds, Adapters) and liner plates will
need to be removed and most likely replaced. At this time the dipper base material underneath the GET
components and liners would be inspected thoroughly using this document. However it may also be necessary to
remove liner plates during preventative maintenance checks if it appears that cracks are propagating underneath
liner plates (C). Depending on the amount of cracking it may be necessary to remove the dipper and repair in a
dedicated repair shop.
Inspection & Salvage By Component
Teeth & Shrouds
(A) Upper Corner Shrouds
(B) Lower Corner Shrouds
(T) Tooth
(S) Shrouds
Table 7
Measurement of Ground Engaging Tools (GET)
Tooth Position T9 T8 T7 T6 T5 T4 T3 T2 T1
Actual
Measurement
Shroud
S8 S7 S6 S5 S4 S3 S2 S1
Position
Actual
Measurement
Teeth and Shrouds should be measured and documented using a form which looks similar to Illustration 18 and
Table 7.
Minimum Requirements
Refer to the recommended wear inspection criteria for the specific GET components to be inspected. At a
minimum it is suggested that the tooth length (TL) and Shroud Length (SL) be measured for wear.
Check Minimum Tooth Length = (TL)
Check Minimum Shroud Length = (SL)
The following procedure can be used to perform a general field wear measurement for (TL) and (SL). If
measurements do not meet the minimum CAT GET requirements or appear to be damaged DO NOT USE
AGAIN and replace with new GET components.
If replacing GET components refer to the ""Dipper Lip Wear Measurements" " section of this document.
General Field Measuring Procedure
(T) Teeth slightly raised
Personal injury or death can occur from heavy components falling

during removal or installation.
Properly support the component with a suitable lifting device during

removal or installation.
1. Position Dipper with teeth slightly upward as shown in Illustration 19. Make sure that dipper is firmly
planted in ground or has suitable cribbing to prevent movement during inspection.
Measuring tooth length
2. Measure tooth length (TL) from back edge to the tip as shown in Illustration 20.
Measuring shroud length
3. Measure shroud length (SL) from leading edge of dipper lip to tip of shroud as shown in Illustration 21.
4. If teeth or shrouds are removed the lip should be measured according to the ""Dipper Lip Wear
Measurements" " section of this document before installation of new GET hardware.
Corner Shrouds
Inspect Corner Shrouds (A) & (B) to ensure the following. If corner shrouds do not meet the following criteria
DO NOT USE AGAIN.
All locks appear secure with no movement.
No excessive damage to shroud which will cause dipper lip wear.
No excessive wear to shroud which will require shroud to be replaced before next scheduled preventative
maintenance.
Dipper Lip Inspection
(A) The entire dipper lip casting
(B) Leading edge
(C) Holes for GET hardware
(D) Locations where GET hardware may be welded to lip
(E) Weld joint between lip, front castings, and side plates
First, remove all GET before a thorough inspection of the dipper lip. The entire dipper lip casting (A) should be
inspected for damages and cracks using both visual inspection and Magnetic Particle Inspection (MPI). Refer to
the ""Crack Detection Methods" " section of this document.
Pay particular attention to the following features.
(B) Leading Edge
(C) Holes used for GET hardware
(D) GET components welded to the lip
(E) Weld joint between the lip, front castings, and side plates.
In order to inspect the dipper lip for sizing GET hardware refer to the ""Dipper Lip Wear Measurements" "
section of this document.
Example of cracks found in lip
(F) Crack found near weld between GET component and lip
(G) Crack found near weld between dipper lip and front castings
(H) Crack in corner radius of hole for GET
(J) Crack found in leading edge
Refer to Illustration 23 which lists several examples of different defects found in several locations on the dipper
lip.
Dipper Lip Weld Detail & Salvage
Dipper lip weld joint details
NOTICE
Hard faced overlay weld should not contact dipper lip, front castings,
or side plate material. Refer to (S), (T), and (U) shown in Illustration
24.
Repair any cracks found according to the ""Crack Repair" " section of this document. Refer to Illustration 24
and Tables 8 and 9 for weld details and parameters required to restore the lip back to its original specifications.
Table 8
Dipper Lip Weld Information
Item Item
Details Details
D 45° P
7.9 mm (0.31 inch)
Add
E R 9.7 mm (0.38 inch) layer of hardfacing electrode (U) over
19.1 mm (0.75 inch)
base weld (T) during installation of liner (S).
F S Liner material
12.7 mm (0.50 inch)
G T Liner structural fillet weld.

50.8 mm (2.0 inch)
Deposit hardface overlay weld material over structural fillet
Requires back gouge, MPI, &
H U weld. Overlay should not contact dipper lip, front castings, or
UT
side plate materials.
Main structural groove welds between lip, side plates, and
J V
44.5 mm (1.75 inch) front castings.
Requires back gouge for length
of
K W Dipper Lip Material
304.8 mm (12.00 inch) from
top of lip casting
Requires back gouge, MPI, &
UT. Blend Grind smooth both
sides
L X Dipper Front Material
660.4 mm (26.00 inch) back
from leading edge for length
shown (N).
Blend Grind to a smooth
Some iron ore applications require liner materials (S) to be on
M radius. No slag inclusions Z
dipper lip.
allowed.
AA
N Manganese Round
660.4 mm (26.00 inch)
Table 9
Welding Parameters for Dipper Lip Fill Passes & Overlay

Welding Electrode
Application Electrode Amps Volts
Process (1) Diameter
E8018-C1 180-300 --
4.8 mm (3/16 inch)
SMAW Groove Welds (V)
E8018-C1 90-160 --
3.2 mm (1/8 inch)
E80T1-Ni1 400-525 27-30

2.4 mm (3/32 inch)
FCAW (2) Groove Welds (V)
E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
E309L-16 110-145 --
4.0 mm (5/32 inch)
SMAW Liner Welds (T)
E309L-16 80-110 --
3.2 mm (1/8 inch)
FCAW (2) Liner Welds (T) ER309LT-1 180-260 24-29

1.2 mm (0.045 inch)
Hardface (3) 100-150 --

3.2 mm (1/8 inch)
SMAW Overlay (U)
Hardface (3) 150-210 --
4.8 mm (3/16 inch)
FCAW (3) Overlay (U) Hardface (3) 200-350 25-28

2.4 mm (3/32 inch)
Min. Preheat Temp.:

204° C (400° F) (4)
Max. Interpass Temp.:

315° C (600° F)
(1) Polarity - DCEP
(2) 100% CO2 Shielding gas.
(3) Electrode with a deposit hardness between 58 & 62 Rockwell C. Refer to Table 52.
(4) Manganese round liners (AA) require no preheat for installation.
Front Leading Edge Inspection
Visual inspection of leading-edge wear plate on FastFillTM dipper.
(A) Chocky type wear bar
(B) Grooves on wear pads
The primary inspection method of leading-edge wear materials is Visual Inspection as shown in Figure 25. If
wear pads have worn down completely to the point where the grooves between pads (B) cannot be seen
anymore, DO NOT USE AGAIN.
Measuring method of leading edge
(A) Typical wear bar on straight sided dipper
(B) Typical Chocky wear bar on FastFillTM dipper
(C) = Min. 25 mm (1.0 inch)

(D) = Min. 10.0 mm (0.39 inch)
If it cannot be determined visually how much wear is present refer to Illustration 26 which indicates the
minimum amount of material which is required to USE AS IS.
Front Leading Edge Installation & Salvage
(A) Gap between chock wear bar sections
(B) Ends of wear bar
(C) Gap between wear bars
(D) Weld blend transition
Refer to Illustration 27 and Table 10 for weld detail information regarding installation of leading edge.
There is no weld allowed on ends of wear bars (B) or between any segmented wear bars (A). Also segmented
wear bars shall have a gap between them (C) with no weld. The weld blend transition (D) should taper from (H)
to 3.0 mm (0.12 inch) at the ends of the wear bar.
Table 10
Dipper Leading Edge Weld Information
Item Size Item Size
G F
6.4 mm (0.25 inch) 127 mm (5.0 inch)
C H
0.8 mm (0.03 inch) 12.7 mm (0.50 inch)
Table 11
Welding Parameters for Dipper Leading Edge
Welding Electrode
E309L-16 110-145 --
4.0 mm (5/32 inch)
SMAW Fillet Welds
E309L-16 80-110 --
3.2 mm (1/8 inch)
FCAW (2) Fillet Welds ER309LT-1 180-260 24-29

1.2 mm (0.045 inch)
Min. Preheat Temp.:

110° C (225° F)

230° C (450° F)
(1) Polarity - DCEP
(2) 100% CO2 Shielding gas
Dipper Back and Front Rear Edge Inspection
Wear location of dipper rear edge and back
(A) Liner
(B) Wear into liner
(C) Fillet weld attaching liner to dipper
(D) Structural plate/casting
An inspection of the dipper back and the rear edge as shown in Illustration 28 shall be performed to ensure that
there is not excessive wear (B). If wear has progressed through the liners (A), the fillet welds (C) to the
structural plate/casting (D) ; DO NOT USE AND REPLACE LINERS.
Dipper Back and Front Rear Edge Salvage
Salvage of dipper back and rear edge
(G) Build-up of worn structural plate
(H) Liner plate welds
(J) Overlay
NOTICE
Deposit hardface overlay (J) weld material over liner plate fillet (H)
and liner material only. If hardface overlay contacts dipper parent
material it can cause cracking.
If dipper back and/or rear edge are worn into the dipper structural plate then remove liner and buildup areas (G)
as required. Use a straight edge to determine the amount of build-up required. Refer to Illustration 29 and Table
12 for salvage information.
Table 12
Welding Parameters for Dipper Back and Rear Edge
Welding Electrode Volts
Application Electrode Amps
180-300
4.8 mm (3/16 inch) E8018-C1 --
SMAW Build-up (G)
90-160
E8018-C1 --
3.2 mm (1/8 inch)
400-525 27-30
2.4 mm (3/32 inch) E80T1-Ni1
FCAW (2) Build-up (G)

100-300 24-25
1.3 mm (0.052 E81T1-Ni2
inch)
SMAW Liner Plates Welds E309L-16 110-145 --
(H) 4.0 mm (5/32 inch)
E309L-16 80-110 --
3.2 mm (1/8 inch)
Liner Plates Welds 180-260 24-29

FCAW (2) 1.2 mm (0.045 ER309LT-1
(H)
inch)
100-150
3.2 mm (1/8 inch) Hardface (3) --
SMAW Overlay (J)
150-210
Hardface (3) --
4.8 mm (3/16 inch)
200-350 25-28
FCAW (3) Overlay (J) 2.4 mm (3/32 inch) Hardface (3)
Min. Preheat Temp.:

110° C (225° F) Dipper Rear Edge 204° C (400° F)
Dipper Back
Max. Interpass
Temp.: 230° C (450° F) 316° C (600° F)
(1) Polarity - DCEP
Latch Keeper Inspection
(A) Bottom outside view of latch keeper
(B) Top inside view of latch keeper
(C) Cracks in wear bar mounting holes
(D) Cracks in corners
(E) Cracks in welds
(F) Cracks in welds between liner wear plates
Inspect both the top and bottom sides of latch keeper for cracks or excessive damage and wear. Refer to the
""Crack Detection Methods" " section of this document.
Latch Keeper Salvage
Latch Keeper weld joint details for salvage welding
Refer to Tables 13 through 14 for details.
Table 13
Latch Keeper Weld Information
Item
Details
D 45°
E
69.85 mm (2.75 inch)
F
12.7 mm (0.50 inch)
G
63.5 mm (2.50 inch)
H
57.2 mm (2.25 inch)
Requires back gouging, MPI, & UT. Refer to the ""Crack Detection Methods" " section of this
J
document.
K
9.7 mm (0.38 inch)
L Add weld layer thickness (K) of hardfacing electrode on top of structural fillet weld (P)
M Structural groove weld
Table 14
Welding Parameters for Fill Passes & Overlay of Latch Keeper
Welding Electrode
E8018-C1 180-300 --
4.8 mm (3/16 inch)
SMAW Fill Pass (M)
E8018-C1 90-160 --
3.2 mm (1/8 inch)
E80T1-Ni1 400-525 27-30

2.4 mm (3/32 inch)
FCAW (2) Fill Pass (M)
E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
E309L-16 110-145 --
4.0 mm (5/32 inch)
SMAW Liner Plate Welds (P)
E309L-16 80-110 --
3.2 mm (1/8 inch)
FCAW (2) Liner Plate Welds (P) ER309LT-1 180-260 24-29

1.2 mm (0.045 inch)
Hardface (3) 100-150 --

3.2 mm (1/8 inch)
SMAW Overlay (L)
Hardface (3) 150-210 --
4.8 mm (3/16 inch)
FCAW Overlay (L) Hardface (3) 200-350 25-28

2.4 mm (3/32 inch)
Min. Preheat Temp.:

204.4° C (400° F)

315° C (600° F)
(1) Polarity - DCEP
Padlock Connection Bore Inspection
Measuring eccentric bushing wear
(A) Eccentric bushing
If bushing does not meet the minimum thickness requirements in the primary wear area (D), then remove
bushing and inspect bore for damages. Refer to Illustration 33.
Table 15
Padlock Bushing Dimensional Requirements
Location Required Dimensions and Tolerances
B 45°
C Min.
202.9 mm (7.99 inch)

Max.
203.5 mm (8.01 inch)
Min.
D (1)
25.4 mm (1.00 inch)
(1) Bushing needs to last until the next scheduled rebuild. Therefore bushing replacement may be required before it reaches the
minimum thickness in order to keep from damaging the bore.
Visual inspection of padlock bores with bushing removed
(A) Minor gouging to bore due to bushing removal
(B) Slight heat damage due to bushing removal
(C) Crack in weld between main lug plate and hub plate
Typical flapper wheel type tool used to dress burrs
NOTICE
Remove bushing by air carbon arc gouging welds. Minimize the
amount of lug/bore material that is gouged or damaged. Refer to
locations (A) and (B) in Illustration 33.
Inspect bore and welds around hub plate (C) visually for any signs of damage including burrs, cracks, smearing,
or oval conditions. After visual inspection inspect bore and weld using one of the ""Crack Detection Methods" "
listed in this document. If no defects are found during visual inspection, proceed with dimensional inspections.
If burrs or minor protrusions are found on the bore inside diameter a light abrasive type flapper wheel can be
used to restore the surface. Refer to Illustration 34.
NOTICE
Do Not use heavy abrasives to dress inside diameter which may remove
excessive material and cause the bore to be out of the specified
diameter. Ensure that the bore dimensions are measured after any
dressing of burrs or protrusions.
Padlock Bores Dimensional Inspection
Padlock bore and lug dimensional requirements
Refer to the Measurement Techniques section of this document.
Inspect bore diameters and widths according to Figure 35 and Table 16. If bores do not meet the required
dimensions and tolerances refer to the ""Bore Build-up and Salvage Welding" " section of this document.
Table 16
Padlock Bore and Lug Dimensional Inspection
Min.
406.1 mm (15.99 inch)
B
Max.
406.7 mm (16.01 inch)
Min.
285.60 mm (11.244 inch)
C
Max.
285.65 mm (11.246 inch)
12.19 mm (0.48 inch) Diameter

D
19.1 mm (0.75 inch) Deep.
Near side, far side in eight places.
E
9.7 mm (0.38 inch) by 45° Chamfer both sides.

Min.
177.5 mm (6.99 inch)
H
Max.
178.1 mm (7.01 inch)
Front Castings Weld Inspection & Salvage
Table 17
Front Castings Weld Information
Item
Details
The front castings require both visual inspection and MPI, refer to the ""Crack Detection Methods" "
B
section of this document. (1)
C 45°
D
102 mm (4.0 inch)
Joint requires back gouge and MPI. Refer to the ""Crack Detection Methods" " section of this
E
document.
G
6.4 mm (0.25 inch) Fillet all around. (Typical for
12.7 mm (0.50 inch) thick liners)
7.9 mm (0.31 inch) Fillet all around (Typical for

H
12.7 mm (0.50 inch) Typical gap between liner plates.
L Liner plate
6.4 mm (0.25 inch) Hardfacing overlay (Typical for

12.7 mm (0.50 inch) thick liner plates)
M
9.7 mm (0.38 inch) Hardfacing overlay (Typical for

6.4 mm (0.25 inch) Fillet all around. (Typical for

N
7.9 mm (0.31 inch) Fillet all around (Typical for

(1) If liner plates (L) are worn it is suggested that they are removed so that the dipper base material underneath can be inspected.
Table 18
Welding Parameters for Fill Passes & Overlay of Front Castings
Welding
Electrode
Process (1) Application Electrode Amps Volts
Diameter
4.8 mm (3/16 inch) E8018-C1 180-300 --

Fill Pass
SMAW
Repair Welds (C)
E8018-C1 90-160 --
3.2 mm (1/8 inch)
2.4 mm (3/32 inch) E80T1-Ni1 400-525 27-30

(2) Fill Pass
FCAW
Repair Welds (C)
E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
SMAW Primary Welds for Liner Plates
(N) 4.0 mm (5/32 inch) E309L-16 110-145 --
E309L-16 80-110 --
3.2 mm (1/8 inch)
FCAW (2) ER309LT-1 180-260 24-29

1.2 mm (0.045 inch)
Hardface (3) 100-150 --

3.2 mm (1/8 inch)
SMAW Overlay (M)
Hardface (3) 150-210 --
4.8 mm (3/16 inch)
Hardface (3)
FCAW Overlay (M) 2.4 mm (3/32 inch) 200-350 25-28
Min. Preheat Temp.:

204.4° C (400° F)

315° C (600° F)
(1) Polarity - DCEP
Heel Band Inspection
Heel band visual example
(A) Crack in plug weld
(B) Crack in outer perimeter fillet of heelband
(C) No weld area near split line
(D) No weld area on ends
Inspect both visually and with MPI or PT including all plug welds (A) and fillet welds (B). There should be no
welds across the split line of two mating heel band parts (C) or at the ends of the heel band parts (D). Welds
should be blended and tapered as shown in Illustration 37 location (C) .
Heel Band Installation & Salvage
Dipper Heel Band weld details
(E) End of Heel Band
(F) Gap between mating Heel Bands
(G) No Weld
(H) Tapered weld transition
Table 19
Heel Band Details
Location
Min. Max.
A
227.1 mm (8.94 inch) 230.1 mm (9.06 inch)
B
544.6 mm (21.44 inch) 547.6 mm (21.56 inch)
Location Location
Weld Size & Details Weld Size & Details
Maximum gap
C F
19.1 mm (0.75 inch) 1.5 mm (0.06 inch) (No Weld)
No fillet weld allowed across split line of mating heel
D G
25.4 mm (1.00 inch) band segments
E No weld on ends of heel H Taper and blend grind ends of welds
band.
NOTICE
Do not weld across the split line of two mating heel band segments (G)
as this could cause cracking into the dipper base material.
Table 20
Welding Parameters for Heel Bands
Welding Electrode
E8018-C1 180-300 --
Fillet Welds 4.8 mm (3/16 inch)
SMAW
Plug Welds
E8018-C1 90-160 --
3.2 mm (1/8 inch)
E80T1-Ni1 400-525 27-30

Fillet Welds 2.4 mm (3/32 inch)
FCAW (2)
Plug Welds
E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
Min. Preheat Temp.:

204° C (400° F)

315° C (600° F)
(1) Polarity - DCEP
Pitch Brace & Handle Connection Bore Inspection
Measuring pitch brace and handle bushings
(A) Bores
(B) Bushings
(C) = 9.53 mm (0.375 inch) Minimum
Minimum Thickness Requirement
NOTICE
Bushing needs to last until the next scheduled rebuild. Therefore
bushing replacement may be required before it reaches the minimum
thickness in order to keep from damaging the bore.
If pitch brace and handle bushings do not meet the minimum thickness requirements (C) in any section of the
circumference then remove bushing and inspect bore for damages. Refer to Illustration 40.
Visual inspection of pitch brace and handle connections
(A) Handle connection lugs
(B) Pitch brace connection lugs
(C) Gouge due to bushing weld removal
(D) Weld between lug and hub plate

(E) Slight heat damage due to bushing removal
NOTICE
locations (C) and (E) in Illustration 40.
Inspect bores and welds around hub plate (D) visually for any signs of damage including burrs, cracks,
smearing, or oval conditions. After visual inspection inspect bore and weld using one of the ""Crack Detection
Methods" " listed in this document. If no defects are found during visual inspection, proceed with dimensional
inspections.
NOTICE
DO NOT use heavy abrasives to dress inside diameter which may
remove excessive material and cause the bore to be out of the specified
Pitch Brace & Handle Connection Bore Dimensional Inspection
(A) Handle connection bores
(B) Pitch brace connection bores
Refer to the ""Measurement Techniques" " section of this document.
Inspect bore diameters and widths according to Figure 41 and Table 21. If bores do not meet the required
Table 21
Pitch Brace and Handle Lug Dimensional Inspection
Min.
241.1 mm (9.492 inch)
G (1)
Max.
241.15 mm (9.494 inch)
Min.
204.5 mm (8.05 inch)
H (2)
Max.
204.7 mm (8.06 inch)
Min.
171.2 mm (6.74 inch)
J
Max.
171.7 mm (6.76 inch)
Min.
323.6 mm (12.74 inch)
K
Max.
324.1 mm (12.76 inch)
Min.
88.6 mm (3.49 inch)
L
Max.
89.2 mm (3.51 inch)
Min.
126.7 mm (4.99 inch)
M
Max.
127.3 mm (5.01 inch)
Min.
1246.9 mm (49.09 inch)
N
Max.
1248.9 mm (49.17 inch)
P
9.70 mm (0.38 inch) X 45° Chamfer both sides
(1) Bore inside diameter.
(2) Bushing inside diameter.
Door Hinge Bore Inspection
(A) Bores
(B) Bushings
(C) 9.53 mm (0.375 inch) Minimum thickness.
Minimum Thickness Requirement
NOTICE
Bushing needs to last until the next scheduled rebuild. Therefore
bushing replacement may be required before it reaches the minimum
thickness in order to keep from damaging the bore.
If door hinge bushings do not meet the minimum thickness requirements (C) in any section of the circumference
then remove bushing and inspect bore for damages. Refer to Illustration 42
Refer to Illustration 43 for bore inspection.
Door Hinge Bore
(F) Welds for lug plate
(G) Cracks near hinge bores
(H) Slight heat damage due to bushing removal.
NOTICE
location (H) in Illustration 43.
Inspect bores and welds around hub plate (F) visually for any signs of damage including burrs, cracks, smearing,
or oval conditions. After visual inspection inspect bore and weld using one of the ""Crack Detection Methods" "
listed in this document. If no unacceptable defects are found proceed with dimensional inspections.
NOTICE
Door Hinge Bore Dimensional Inspection
Door Hinge Bores
Refer to the ""Measurement Techniques" " section of this document.
Inspect bore diameters and widths according to Illustration 44 and Table 22. If bores do not meet the required
Table 22
Door Hinge Bore Dimensional Inspection
Location Required Dimensions and Tolerances Location Required Dimensions and Tolerances
Min. Min.
2303.5 mm (90.69 inch) 241.10 mm (9.492 inch)
G K
Max. Max.
2307.1 mm (90.83 inch) 241.15 mm (9.494 inch)
Min. Min.
190.2 mm (7.49 inch) 204.5 mm (8.05 inch)
H L
Max. Max.
190.8 mm (7.51 inch) 204.7 mm (8.06 inch)
J Min. -- --
155.4 mm (6.12 inch)
Max.
--
156.0 mm (6.14 inch)
Snubber Components & Visual Inspection
Snubber Parts
A new and improved snubber design is available which resists heat build-up on friction discs improving disc
wear properties. Refer to Illustration 45 and Table 23 which details the major parts differences.
Table 23
Snubber Parts
Previous Snubber Design New Improved Snubber Design
Item Part Number Item Part Number
Description Description
1 Link C111960-01 1 Link C111960-01

2 Pin S067010 2 Pin 451-7093
3 Friction Plates C116397-21 3 Friction Plates C116397-21
4 Friction Disc B005926-01 14 (1) Friction Disc 477-3220
Outboard Pressure Plate 15 (1) Outboard Pressure Plate

5 C104459-05 478-7816
6 Housing C114686-01 16 (1) Housing 478-2512
7 Cover B007265-01 17 (1) Cover 477-3222
8 Hex Nut B007264-01 18 (1) Hex Nut 478-7550
9 Washer 03952950 19 (1) Washer 147-2383
10 Bolt B007263-01 20 (1) Bolt 478-7546
11 End Cap C110597-01 21 (1) End Cap 477-3223
12 Snubber Pads 82020265 22 (1) Washer Stack 477-3215
13 Snubber Support C111994-01 13 Snubber Support C111994-01

(1) Parts required to convert to new design.
Snubber visual inspection requirements
(1) Snubber Link
(2) Pin
(3) Friction Plates
(4) (14) Friction Discs
(6) (16) Housing
(AA) Weld
(AB) Bore
(AC) Pin surface
(AD) Friction Plate surface
(AE) Friction Plate wear transition
(AF) Broken/Scaling Friction Disc material
(AG) Deep grooves worn in housing
Inspect the welds (AA) for cracks and the bores (AB) of the link for scoring or damage.
Inspect the pin surface (AC) and the Friction Plate (AD) for damage or distortion. If significant wear is found at
the transition area (AE) of the Friction plate, DO NOT USE AGAIN.
If the ceramic coating of the friction disc appears to be scaling or broken, DO NOT USE AGAIN.
If significant scoring or wear marks (AG) are found in Housing (6) or (16), then DO NOT USE AGAIN.
Snubber Components Dimensional Inspection & Salvage
Required dimension for Snubber Link and Pins
(1) Snubber Link
(2) Pins
Table 24
Snubber Link and Pins Dimensional Inspection
AH Min. AK Min.
101.780 mm (4.007 inch) 101.2 mm (3.98 inch)

Max. Max.
101.90 mm (4.012 inch) 101.6 mm (4.00 inch)
Min.
736.1 mm (28.98 inch)
AJ AL
Max. 19.1 mm (0.75 inch)
737.1 mm (29.02 inch)
Snubber Base and Pressure Plates
(5) Outboard Pressure Plate
(13) Snubber Support
(15) Outboard Pressure Plate
(23) Inboard Pressure Plate
Table 25
Snubber Base and Pressure Plates Dimensional Inspection
Location Required Dimensions and Location
Required Dimensions and Tolerances
Tolerances
Min.
AU
203.45 mm (8.010 inch) 3.0 mm (0.12 inch) x 45° Chamfer
AM
Max.
203.70 mm (8.020 inch) 31.8 mm (1.25 inch)
AV
Min.
226.90 mm (8.933 inch) 38.1 mm (1.50 inch)
AN
Max.
226.95 mm (8.935 inch) 31.8 mm (1.25 inch)
AW
Min.
203.45 mm (8.010 inch) 38.1 mm (1.50 inch)
AP
Max.
203.70 mm (8.020 inch) 235.0 mm (9.25 inch)
BA
Min.
226.90 mm (8.933 inch) 235.7 mm (9.28 inch)
AR
Max.
226.95 mm (8.935 inch) 222.0 mm (8.74 inch)
BB
Min.
203.20 mm (8.000 inch) 222.5 mm (8.76 inch)
AS
Max.
BC
203.33 mm (8.005 inch) 7.9 mm (0.31 inch)
AT 6.4 mm (0.25 inch) x 45° BD

25.4 mm (1.00 inch)
Chamfer
AU 3.0 mm (0.12 inch) x 45° BG

6.4 mm (0.25 inch)
Chamfer
Fillet weld must be machined flat for distance (BB) for

AT 6.4 mm (0.25 inch) x 45° BH
clearance during assembly.
Chamfer
Friction Plates required dimensions
Table 26
Snubber Friction Plates Dimensional Inspection
Min. Min.
533.1 mm (20.99 inch) 203.45 mm (8.010 inch)
BA BD
Max. Max.
533.7 mm (21.01 inch) 203.70 mm (8.020 inch)
Min. Min.
226.90 mm (8.933 inch) 103.1 mm (4.06 inch)
BB BE
Max. Max.
226.95 mm (8.935 inch) 103.4 mm (4.07 inch)
Min.
--
126.03 mm (4.962 inch)
BC --
Max.
--
126.09 mm (4.964 inch)
Snubber Housing and Discs
Table 27
Snubber Housing, Washers, and Friction Discs Dimensional Inspection
Location
Min.
201.65 mm (7.939 inch)
BG
Max.
201.70 mm (7.941 inch)
BH
10.72 mm (0.422 inch) -
47.8mm (1.88 inch) Deep
12.7 mm (0.50 inch) - 13 UNC-2B-

35.1 mm (1.38 inch) Deep
Place washer stack on floor with recessed tube end facing upward. Measure end face of inner tube
to end face of washer stack (BL).
BL
(BL) Minimum =
7.1 mm (0.28 inch)
Min. Thickness
BM
5.2 mm (0.20 inch) (1)
(1) Uneven wear is unacceptable, if one side is less than 1/2 the thickness on the other side of disc, DO NOT USE AGAIN.
Table 28
Welding Parameters for Link, Friction Plates, & Snubber Support
Welding
Electrode Electrode Volts
Process (1) Application Amps
Diameter
Fillet Welds E8018-C1 90-160

SMAW 3.2 mm (1/8 --
Cracks inch)
Bore Build-up
FCAW (2) of Link, Friction Plates, and Snubber E81T1-Ni2 100-300 24-25
Supports 1.3 mm (0.052
inch)
Min. Preheat Temp.:

107° C (225° F)

204.4° C (400° F)
(1) Polarity - DCEP
Dipper Door Inspection
Examples of defects found in LatchFreeTM dipper door
(D) Cracks in weld toe of door snubber lug
(E) Cracks in weld toe along door arm
(F) Crack in radius of door slot
(G) Cracks in outside corner welds near top of door slot
(H) Crack in weld toe of bore
Examples of defects found in LatchFreeTM dipper door
(H) Cracks in center box section weld
(J) Cracks in bottom left gussets
(K) Cracks in welds near door hinge
(L) Severe damage on lower left door plate
Refer to Illustrations 51 and 52 indicating examples of defects and damages found in LatchFreeTM dipper door.
Inspect all bores, welds, and plates for defects or damages. Refer to the ""Crack Detection Methods" " section of
this document.
LatchFree TM Door Dimensional Inspection
Required Dimensions of LatchFreeTM Dipper Door
Refer to Illustration 53 and Table 29 for required dimensional information. If bushings are damaged or do not
meet dimensional requirements then remove bushings and inspect bore.
Table 29
Dipper Door Dimensional Inspection

Min.
774.2 mm (30.48 inch)
E
Max.
775.2 mm (30.52 inch)
Min.
1608.6 mm (63.33 inch)
F
Max.
1611.1 mm (63.43 inch)
Min.
2322.6 mm (91.44 inch)
G
Max.
2325.6 mm (91.56 inch)
Min.
171.5 mm (6.75 inch)
H
Max.
171.7 mm (6.76 inch)
Min.
241.1 mm (9.492 inch)
J
Max.
241.15 mm (9.494 inch)
Min.
203.7 mm (8.02 inch)
K
Max.
203.5 mm (8.01 inch)
Min.
126.03 mm (4.962 inch)
L
Max.
126.09 mm (4.964 inch)
Min.
234.7 mm (9.24 inch)
M
Max.
235.2 mm (9.26 inch)
Min.
103.10 mm (4.06 inch)
N
Max.
103.4 mm (4.07 inch)
R Min.
241.1 mm (9.492 inch)
Max.
241.15 mm (9.494 inch)
Min.
203.7 mm (8.02 inch)
S
Max.
203.5 mm (8.01 inch)
T
9.7 mm (0.38 inch) X 45° Chamfer all around both sides.
Dipper Door Weld Details & Salvage
LatchFreeTM Dipper Door
Table 30
LatchFreeTM Dipper Door Weld & Salvage Information
Location
B
19.1 mm (0.75 inch)
C
9.7 mm (0.38 inch)
D Liner plate
F Door material
Bottom toe weld-pass against door material (F) to be stainless electrode type E309. Refer to
G
Illustration 54 and Table 31.
Hardfacing overlay weld electrode, DO NOT allow hardfacing material to contact door material
H
(F).
J Primary structural plug weld attaching liner to door material.
L
6.3 mm (0.25 inch)
M
6.3 mm (0.25 inch)
N
6.3 mm (0.25 inch)
P
76.2 mm (3.00 inch)
R (1)
88.9 mm (3.50 inch)
S
12.7 mm (0.50 inch) Typical between liner plates.
T
6.3 mm (0.25 inch) Typical all around liner plates.
Requires back gouge and MPI. Refer to the ""Crack Detection Methods" " section of this
W
document. Weld to be ground flush on outside with smooth concave radius on inside.
X
31.8 mm (1.25 inch)
Y
76.2 mm (3.00 inch)
Requires back gouge and MPI. Weld to be profile ground, refer to the ""Profile Grinding" "
Z
AB
355.6 mm (14.00 inch)
AC
76.2 mm (3.00 inch)
AD Welds connecting door hinge to door
(1) Position door liner plates 38.1 mm (1.50 inch) above top of dipper floor without liners.
Table 31
Welding Parameters for LatchFreeTM Dipper Door
Welding
Electrode Volts
Process (1) Application Electrode Amps
Diameter
180-300
E8018-C1 --
4.8 mm (3/16 inch)
SMAW
E8018-C1 90-160 --
Repairs to Structural 3.2 mm (1/8 inch)
Plates E80T1-Ni1 400-525 27-30
FCAW (2) 2.4 mm (3/32 inch)
100-300 24-25
E81T1-Ni2
1.3 mm (0.052 inch)
110-145
E309L-16 --
4.0 mm (5/32 inch)
SMAW
Primary Welds
E309L-16 80-110 --
(J), (G) 3.2 mm (1/8 inch)
FCAW (2) ER309LT-1 180-260 24-29

1.2 mm (0.045 inch)
Hardface (3) 100-150

--
3.2 mm (1/8 inch)
SMAW Hardfacing
150-210
Overlay Welds Hardface (3) --
4.8 mm (3/16 inch)
(H)
FCAW (2) Hardface (3) 200-350 25-28
2.4 mm (3/32 inch)
Location AD
Welds to door hinge 110° C (225° F)
Min. Preheat Temp.:
All other plates that make up
door 79.4° C (175° F)
Max. Interpass Temp.: All locations

230° C (450° F)
(1) Polarity - DCEP
Dipper door latch style
Table 32
Latched Door Weld & Salvage Information
Location
B
19.1 mm (0.75 inch)
C
9.7 mm (0.38 inch)
D Liner plate
F Door material
Bottom toe weld-pass against door material (F) to be stainless electrode type E309. Refer to Table
G
Dipper Door Weld Parameters
Hardfacing overlay weld electrode, DO NOT allow hardfacing material to contact door material
H
(F).
J Primary structural plug weld attaching liner to door material.
L
6.3 mm (0.25 inch)
M
6.3 mm (0.25 inch)
N
6.3 mm (0.25 inch)
P
76.2 mm (3.00 inch)
R (1)
88.9 mm (3.50 inch)
S
12.7 mm (0.50 inch) Typical between liner plates.
T
6.34 mm (0.25 inch) Typical all around liner plates.
Requires back gouge and MPI. Refer to the ""Crack Detection Methods" " section of this
W
document. Weld to be ground flush on outside with smooth concave radius on inside.
X
31.8 mm (1.25 inch)
Y
76.2 mm (3.00 inch)
Z Requires back gouge and MPI. Weld to be profile ground, refer to the ""Profile Grinding" "
AB
355.6 mm (14.00 inch)
AC
76.2 mm (3.00 inch)
AE Welds connecting door hinge to door
(1) Position door liner plates 38.1 mm (1.50 inch) above top of dipper floor without liners.
Table 33
Welding Parameters for Latched Dipper Door
Welding
Electrode Volts
Process (1) Application Electrode Amps
Diameter
180-300
E8018-C1 --
4.8 mm (3/16 inch)
SMAW
E8018-C1 90-160 --
Repairs to Structural 3.2 mm (1/8 inch)
Plates E80T1-Ni1 400-525 27-30
FCAW (2) 2.4 mm (3/32 inch)
100-300 24-25
E81T1-Ni2
1.3 mm (0.052 inch)
110-145
E309L-16 --
4.0 mm (5/32 inch)
SMAW
Primary Welds E309L-16 80-110 --
3.2 mm (1/8 inch)
(J), (G)
FCAW (2) ER309LT-1 180-260 24-29
1.2 mm
(0.045 inch)
Hardface (3) 100-150

--
3.2 mm (1/8 inch)
SMAW Hardfacing
150-210
Overlay Welds Hardface (3) --
4.8 mm (3/16 inch)
(H)
FCAW (2) Hardface (3) 200-350 25-28
2.4 mm (3/32 inch)
Location AD
Welds to door hinge 110° C (225° F)
Min. Preheat Temp.:
All other plates that make up
door 79.4° C (175° F)
Max. Interpass Temp.: All locations

230° C (450° F)
(1) Polarity - DCEP
(AH) Latch Bar Wear Guides
(AJ) Optional open latch bar access
If latch bar wear guides (AH) are replaced regularly there should be little build-up or repair required in the door
latch bar area. Some applications require access to latch bar from the back of door (AJ) for easy removal of
debris.
Latch Bar Inspection
(A) Latch Bar with weld overlay
(B) Latch Bar with removable insert
(C) Entire Latch Bar
(D) Area where Latch Arm contacts
(E) Primary wear area
Refer to Illustration 57 for inspection information. Some Latch Bars have a hardened weld overlay in the wear
area (A), while others may have a removable insert (B) with hardened weld overlay on one surface.
Inspect the entire latch bar (C) both visually and using MPI or PT. Refer to the ""Crack Repair " " section of this
document.
Inspect latch arm contact area (D) and area that wears against latch keeper (E) for excessive wear. If excessive
wear or damage is present, DO NOT USE AGAIN.
Latch Bar Details and Salvage
Latch bar required dimensions
(A) Latch Bar
(L) No Insert Welded Latch Bar
(M) Bolted Insert Latch Bar
(N) Insert
Refer to Illustration 58 and 59 and Tables 34 and 35 for repair and salvage information of the latch bar (A).
Table 34
Latch Bar Weld & Salvage Information
C
54 mm (2.13 inch)
D
27mm (1.06 inch) Radius
E 15°
F
375 mm (14.75 inch)
G
35.1 mm (1.38 inch) Diameter
H
31.8 mm (1.25 inch)
J
51 mm (2.0 inch) Radius
K 35°
R
6.4 mm (0.25 inch)
S
85.9 mm (3.38 inch)
T
176.05 mm (6.931 inch)
Min.
101.63 mm (4.001 inch)
U
Max.
101.75 mm (4.006 inch)
Min.
50.93 mm (2.005 inch)
V
Max.
50.67 mm (1.995 inch)
W Min.
25.1 mm (0.99 inch)

Max.
25.7 mm (1.01 inch)
25.7 mm (1.01 inch)

X
26.7 mm (1.05 inch)
Y
3.8 mm (0.15 inch) x 45° chamfer both sides.
Z
12.7 mm (0.50 inch) Radius both sides.
22.23 mm (0.875 inch) Drill thru

AA
1.00 inch -8 UNC-2B,
64 mm (2.5 inch) Deep, Qty 3.
Min.
108.08 mm (4.255 inch)
AB
Max.
108.08 mm (4.255 inch)
Min.
108.08 mm (4.255 inch)
AC
Max.
108.08 mm (4.255 inch)
AD
44.5 mm (1.75 inch)
Table 35
Welding Parameters for Repair of Latch Bar
Welding Electrode
E8018-C1 180-300 --
4.8 mm (3/16 inch)
SMAW Repair
E8018-C1 90-160 --
3.2 mm (1/8 inch)
E80T1-Ni1 400-525 27-30

2.4 mm (3/32 inch)
FCAW (2) Repair
E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
SMAW Overlay (L) Hardface (3) 100-150 --
3.2 mm (1/8 inch)
Hardface (3) 150-210 --

4.8 mm (3/16 inch)
FCAW Overlay (L) Hardface (3) 200-350 25-28

2.4 mm (3/32 inch)
Min. Preheat Temp.:

121° C (250.° F)

204.4° C (400° F)
(1) Polarity - DCEP
Latch Bar Insert
Table 36
Latch Bar Insert Weld & Salvage Information
Min.
25.1 mm (0.99 inch)
AH
Max.
25.70 mm (1.01 inch)
Min.
25.1 mm (0.99 inch)
AJ
Max.
25.70 mm (1.01 inch)
AK
9.7 mm (0.38 inch) thick overlay.
SMAW Overlay (N)
Hardface (3) 100-150 --
3.2 mm (1/8 inch)
Hardface (3) 150-210 --

4.8 mm (3/16 inch)
FCAW Overlay (N) Hardface (3) 200-350 25-28

2.4 mm (3/32 inch)
Min. Preheat Temp.:

52° C (125° F)

204° C (400° F)
Latch Arm Inspection
Latch Arm Inspection
(A) Latch Arm with bushing
(B) Wear area in contact with Latch Bar
(C) Bushing
(D) Dipper Trip Hole
Inspect the Latch Arm with bushing (A) for overall damage or cracks. Refer to the ""Crack Detection Methods"
" section of this document for more information. Visually inspect the bushing for damage or excessive wear.
Inspect the area that contacts the Latch Bar (B) and the Dipper Trip Hole (D) to see if excessive wear is present.
If excessive wear or cracks are present, DO NOT USE AGAIN. If Latch Arm inspection reveals no major
damage or only bushing wear refer to the ""Latch Arm Required Dimensions and Salvage." " section of this
document.
Latch Arm Required Dimensions and Salvage

Latch Arm required dimensions
Table 37
Latch Arm Dimensional Requirements
Location
P
6.4 mm (0.25 inch)
Min.
47.5 mm (1.87 inch)
R1
Max.
54.1 mm (2.13 inch)
Blend grind to approximately
25.4 mm (1.00 inch) Radius. Finish should be coarse ground with uniform contour free of surface
R2
irregularities, abrupt transitions, nicks, notches, and gouges. Minor indentations to have gradual
blends.
Min.
139.52 mm (5.493 inch)
U
Max.
139.57 mm (5.495 inch)
V Min.
2612.9 mm (102.87 inch)
Max.
2625.6 mm (103.37 inch)
Min..
249.2 mm (9.81 inch)
W
Max.
258.8 mm (10.19 inch)
X
12.7 mm (0.50 inch)
Min.
63.37 mm (2.495 inch)
Y
Max.
63.63 mm (2.505 inch)
Z
787.4 mm (31 inch) x 45° Chamfer both sides.
Measure required dimensions as shown in Illustration 62 and Table 37. If bushing is worn remove from Latch
Arm and measure bore diameter (U). Inspect using MPI to insure no cracks, refer to the ""Crack Detection
Methods" " section of this document.
LatchFreeTM Link Bore Inspection
(A) Cracks near camshaft mounting bores
(B) Cracks near eccentric mounting bores
Areas near the camshaft and eccentric bores should first be inspected and repaired before dimensional checks or
measurement are performed. Refer to Illustration 63 which lists examples of defects found.
Repair any cracks found according to the ""Crack Repair" " section of this document.
Camshaft and Eccentric bore inspection
(A) Camshaft bore with no major defects
(B) Scoring or grooves in eccentric bores
(C) Abrasive wear in eccentric bores
(D) Metal flow at split line of cap
Inspect bores visually for any defects or damages. If scoring or grooves (B) are found in the bore surfaces, use a
seal pick to check for depth. Drag a seal pick across the groove and if the groove stops the pick, DO NOT USE
AGAIN.
NOTICE
If minimal abrasive wear or scratches are found (C) in any bore, dress bore inside diameter with a light abrasive
type flapper wheel to restore the surface.
LatchFreeTM Link and LatchFreeTM Door Hinge Bores Dimensional Inspection
Bearing cap match marks
(A) Stamped marks match
NOTICE
Before any measurements or machining is performed, ensure that the

match mark numbers for the bearing blocks match the dipper back as
shown in Illustration 65. Also ensure that the bearing cap bolts are
properly torqued to specification before inspection or machining.
Required dimensions for LatchFree Link and LatchFree door hinge bores
Section views of LatchFree Link and LatchFree door hinge bores.
Table 38
LatchFreeTM Link and LatchFreeTM Door Hinge Bores Dimensional Requirements
AA Min.
1094.77 mm (43.101 inch)

Max.
1092.45 mm (43.010 inch)
Min.
393.57 mm (15.495 inch)
AB
Max.
393.71 mm (15.5005 inch)
Min.
723.77 mm (28.495 inch)
AC
Max.
724.03 mm (28.505 inch)
Min.
89.94 mm (3.541 inch)
AE
Max.
90.20 mm (3.551 inch)
Min.
143.00 mm (5.630 inch)
AF
Max.
143.10 mm (5.634 inch)
Min.
AG
35.1 mm (1.38 inch)
Min.
1035.69 mm (40.775 inch)
AK
Max.
1036.19 mm (40.795 inch)
Min.
763.70 mm (30.067 inch)
AM
Max.
763.96 mm (30.077 inch)
Min. 29.88°
AP
Max. 30.12°
Min.
155.4 mm (6.12 inch)
AS
Max.
156.0 mm (6.14 inch)
AT Min.
190.2 mm (7.49 inch)
Max.
190.8 mm (7.51 inch)

Min.
241.10 mm (9.492 inch)
BA (1)
Max.
241.15 mm (9.494 inch)
Min.
204.5 mm (8.05 inch)
BB (2)
Max.
204.7 mm (8.06 inch)
Min.
209.967 mm (8.2664 inch)
BC
Max.
210.012 mm (8.2682 inch)
Min.
106.319 mm (4.1858 inch)
BD
Max.
106.355 mm (4.1872 inch)
Min.
126.87 mm (4.995 inch)
BG
Max.
127.13 mm (5.005 inch)
Min.
63.37 mm (2.495 inch)
BH
Max.
63.63 mm (2.505 inch)
Min.
190.37 mm (7.495 inch)
BJ
Max.
190.63 mm (7.505 inch)
Min.
257.05 mm (10.120 inch)
BK
Max.
257.30 mm (10.130 inch)
Min.
164.97 mm (6.495 inch)
BL
Max.
165.23 mm (6.505 inch)
BM Min.
1151.6 mm (45.34 inch)
Max.
1153.7 mm (45.42 inch)
(1) Bore inside diameter.
(2) Bushing inside diameter.
LatchFreeTM System Components
LatchFree TM components
(A) Rock Guard
(B) Eccentric
(C) Cam Shaft
(D) Outboard Support Bushing Block
(E) Trip Arm
(F) Mounting Bracket
(G) Link
(H) Link Pin
Link Arm inspection
(A) Entire Link Arm structure
(B) Bushing
(C) Pin bores
(D) Cam wear area
The entire Link Arm (A) shall be visually inspected and checked for cracks using MPI or PT per the ""Crack
Detection Methods" " section of this document. The bushing (B) and bores (C) should also be inspected for
damage or excessive wear. If damage or excessive wear is found, refer to the Inspection and Salvage of Link
Assembly document.
LatchFree TM Trip Arm, Camshaft, and Related Components Visual Inspection
(A) Trip Arm
(B) Trip Arm Y-Block
(C) Trip Arm Link
(E) Camshaft
(F) Roller Cam
LatchFree TM Trip Arm, Link, and Block inspection
(A) Trip Arm
(B) Trip Arm Y-Block
(C) Trip Arm Link
(G) Damage to Trip Arm due to Assembly
(H) Wear steps in splines
(J) Seal pick
(K) Worn areas in Trip Arm due to Trip Block
(L) Excessive wear in Trip Arm and Link
Inspect trip arm for overall damage, if severe dents are present (G) review procedures for Disassembly &
Assembly.
Inspect splines between Trip Arm and the Camshaft for excessive wear or steps (H). If wear steps are present,
DO NOT USE AGAIN.
Inspect for damage (K) due to contact from the trip arm Y-block (B). Lightly grind or sand edges of dents and
protruding metal smooth.
If significant wear (L) has extended through the bushing and into the Trip Arm Link (C), DO NOT USE
AGAIN.
Inspect entire Arm structure using MPI or PT per the ""Crack Detection Methods" " section of this document.
LatchFree TM Outboard Bearing Support Block, Camshaft, and Cam Inspection
(E) Camshaft
(F) Roller Cam
(N) Bearing journals of Camshaft
(P) Splines
(R) Step
(S) Roller cam bores
Inspect Outboard Support Bushing Block (D), Camshaft (E), and Roller Cam (F) for overall damage.
Inspect bearing journal surfaces on camshaft (N) for excessive wear, scoring, or other damage. If no defects
present, OK TO USE AGAIN.
Inspect splines (P) on Camshaft for excessive wear or steps (R). If wear steps are present, DO NOT USE
AGAIN.
Inspect roller cam bores (S) for excessive wear or damage. If no defects present, OK TO USE AGAIN.
Inspect all components using MPI or PT per the ""Crack Detection Methods" " section of this document.
LatchFree TM Trip Arm, Trip Arm Block, and Trip Arm Link, Dimensional Inspection & Salvage
LatchFree TM Trip Arm required dimensions
Refer to Illustration 73 and Tables 39 and 40 for dimensional requirements and salvage information regarding
the Trip Arm (A).
Table 39
LatchFree TM Trip Arm Dimensional Requirements & Salvage Information
Min.
1611.6 mm (63.45 inch)
A
Max.
1614.2 mm (63.55 inch)
B Min.
151.1 mm (5.95 inch)
Max.
153.7 mm (6.05 inch)
Min.
62.0 mm (2.44 inch)
C
Max.
65.0 mm (2.56 inch)
Drill 6 Holes
13.49 mm (0.531 inch) to depth of
54.1 mm (2.13 inch)
D
16.0 mm (0.63 inch) - 11 UNC - 2B - to a depth of
31.8 mm (1.25 inch)
Table 40
Welding Parameters for LatchFree TM Trip Arm
Welding Electrode
SMAW E8018-C1 90-160 --

Repairs to 3.2 mm (1/8 inch)
Link Arm Holes or Cracks
FCAW (2) E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
Min. Preheat Temp.:

10° C (50° F)

204° C (400° F)
(1) Polarity - DCEP
LatchFree TM Trip Arm Block required dimensions
(B) Trip Arm Block
(C) Manganese bushings
Table 41
LatchFree TM Trip Arm Block Dimensional Requirements & Salvage Information
Min.
K
35.05 mm (1.380 inch) 3.3 mm (0.13 inch)
E
Max. Min.
L
35.10 mm (1.382 inch) 19.1mm (0.75 inch)
Min.
M Grind flush
41.35 mm (1.628 inch)
F
Max. Min.
P
41.40 mm (1.630 inch) 25.4 mm (1.0 inch)
J 45° -- --
Table 42
Welding Parameters for LatchFree TM Trip Arm Block
Welding
Electrode
Process (1) Application Electrode Amps Volts
Diameter
SMAW 3.2 mm (1/8 inch) E8018-C1 90-160 --

Crack or Bore Repair to Trip Block
E81T1-Ni2 100-300 24-25

FCAW (2) 1.3 mm (0.052
inch)
SMAW 3.2 mm (1/8 inch) E309L-16 80-110 --
Bushing (3)
ER309LT-1 180-260 24-29
FCAW (2) 1.2 mm (0.045
inch)
Min. Preheat Temp.:

52° C (125° F)
204° C (400° F)
(1) Polarity - DCEP
(3) Refer to the Bushing Installation section of this document.
LatchFree TM Trip Arm Link required dimensions
(U) Pin and Cotter-pin
Table 43
LatchFree TM Trip Arm Link Dimensional Requirements & Salvage Information
Min.
35.05 mm (1.380 inch)
S
Max.
35.10 mm (1.382 inch)
Min.
41.22 mm (1.623 inch)
T
Max.
41.28 mm (1.625 inch)
U Do not reuse pin and cotter-pin. Replace with new.
Table 44
Welding Parameters for LatchFree TM Trip Arm Link
Welding Application Electrode Electrode Amps Volts
SMAW E8018-C1 90-160 --

3.2 mm (1/8 inch)
Bore Build-up
FCAW (2) E81T1-Ni2 100-300 24-25
1.3 mm (0.052 inch)
Min. Preheat Temp.:

121° C (250° F)

204° C (400° F)
(1) Polarity - DCEP
Bore Build-up and Salvage Welding
Examples of bores which may require rebuild
(A) Padlock bores
(B) Dipper handle connection bores
(C) Snubber bores
(D) Door connection bores
(E) Pitch brace connection bores
(F) LatchFree component bores
If bores do not meet the visual or dimensional inspections in this document, it is possible to rebuild them by
various welding processes.
Refer to Illustration 77 and the following steps.
Bore restoration process
1. Measure worn or damaged bore (A) .
2. Pre-machine bore to oversized condition (B) .
a. (B) = (A) + (6.4 mm (0.25 inch) to 9.5 mm (0.375 inch)).
3. Weld build-up bore with 2-3 layers minimum (C) .
4. Local stress relieve welded bore with resistance heating blanket system. Refer to the ""Stress Relief" "
5. Re-machine bore to original specifications (D) .
6. Inspect both visually and using MPI or PT as described in the ""Crack Detection Methods" " section of
this document.
Build-up Methods
Bore welded with portable bore welding machine method
The preferred method to build up bores is to use a portable bore welding machine which rotates around the bore
axis. This method also produces a quality weld with minimal defects and a build-up that is easier to machine.
Refer to Illustration 80.
Manual weld build-up method
If a portable weld boring machine cannot be obtained the bores can be welded manually by hand using the.
following technique.
1. Deposit several weld passes around the circumference of the bore in the direction of the axis (E) .
2. Deposit weld passes at the edge of the bore (F) to ensure both the bore inside diameter and face clean up
during machining.
Equipment for Bore Build-up and Machining
Portable equipment
(A) Portable boring bar kit
(B) Portable bore welding kit
Refer to the Major Equipment Tooling section of the Dealer Service Tools Catalogue for applicable tooling.
Table 45 lists some of the related tooling for bore build-up and machining.
Table 45
Related Tooling for Bore Build-up and Machining
Part Number Description
477-3189 Bore Welding System
477-3166 (1) Portable Boring Bar (110V)
477-3167 (1) Portable Boring Bar (240V)

(1) Various bar lengths and additional Tooling is available through Dealer Service Tools.
Bushing Installation
Padlock bushing installation
Typical Pitch Brace, Door Hinge, and Handle Connection Bushings
Table 46
Bushing Installation
B 45°
Min.
202.9 mm (7.99 inch)
C
Max.
203.5 mm (8.01 inch)
D Install bushing so that thickest section is in this location.
E
6.4 mm (0.25 inch) thick welds all around.
F 3.3 mm (0.13 inch)

Top of weld should be below bore face.
G 6.4 mm (0.25 inch) thick welds with

50.8 mm (2.0 inch) Length spaced 90° apart..
(G) Temperature controlled freezer
(H) Dry ice
Refer to Illustrations 84 through 86 and Tables 46 and 47 for information on installing bushings.
Bore and bushing sizes are designed for an interference fit. In order to install bushing it will most likely require
reducing the bushing temperature as well as raising the bore temperature.
Allow the bore and bushing temperatures to adjust back to ambient room temperature before welding.
NOTICE
Bushings shall be installed After any stress relieving is performed on
Bushings shall be installed After any stress relieving is performed on
dipper or dipper door. Do Not expose bushings to stress relief
temperatures.
Table 47
Welding Parameters for Bushing Installation
Welding Electrode
Bushing
SMAW 2.4 mm E309L-16 40-70 --
Groove Welds
(3/32 inch)
Bushing
FCAW (2) 1.20 mm E309LT-1 130-220 25-30
Groove Welds
(0.045 inch)
Min. Preheat Temp.:

107° C (225° F)

149° C (300° F)
(1) Polarity - DCEP
(2) 100% CO2 Shielding Gas.
Crack Repair
All welding parameters, electrodes, and preheats listed in this document shall take precedence over other
documents. Refer to the Bucyrus International Welding Standards or SEBD0512 Caterpillar Service Welding
Guide for general welding equipment and technique requirements.
Defect Removal
Once a defect has been detected it shall be removed by grinding, arc gouging or machining. Cavities which have
been arc gouged shall be chipped or ground to remove the arc gouging slag. Uneven areas caused by arc-
gouging which present pockets to trap slag shall be ground smooth. For other than manganese castings, dye
penetrant or magnetic particle testing shall be used to assure that cracks have been removed.
Arc Gouging Equipment and Techniques
(A) Surface view of crack
(B) Side view of crack
(C) End view of crack
(D) Plane of crack
(E) = 25.4 mm (1.00 inch)
(F) = 6.4 mm (0.25 inch)
(G) = 50.8 mm (2.00 inch)
The use of air-carbon arc gouging for the removal of defects is, in many situations, the best choice. This is due to
the amount of metal which can quickly be removed. This process can also be used in locations which are not
accessible to mechanical metal removers. In order to obtain good results during the removal of defects with the
air-carbon arc process, the following guidelines shall be adhered to:
1. All materials to be arc gouged shall be preheated prior to gouging to the same temperature as that required
for welding. Refer to the specific welding parameters for each location to be welded.
Table 48
Air-Carbon Arc Gouging Parameters
Electrode Diameter Current Range (Amps, DC+)
300-400
6 mm (1/4 inch)
350-450
8 mm (5/16 inch)
450-600
10 mm (3/8 inch)
800-1000
12 mm (1/2 inch)
2. The current ranges listed in Table 48 shall be used depending upon the carbon electrode diameter. A
minimum open circuit voltage of 60V shall be available.
3. In order to prevent cracks from "running" during the arc gouging operation, the following sequences shall
be used for crack removal.
a. Starting in sound base metal approximately 25.4 mm (1.00 inch) (E) from each end of the crack,
gouge toward the center of the crack. The extent of metal removed should be approximately that
shown in Illustration 87.
b. Remove the remainder of the crack between the two gouged end areas to the same depth as the
initial gouges.
c. Repeat sequence a and b in layers approximately 6.4 mm (0.25 inch) deep (F) until the crack is
completely removed. This will necessitate widening the groove toward the top surface as the depth
increases per end view.
Weld Groove Preparation
Single -V-Groove Joint
(R) Minimum Radius = 6.4 mm (0.25 inch)
Double -V-Groove Joint
After assurance of defect removal, the cavity shall be prepared for welding by additional grinding, gouging, or
machining as required in order to shape cavity into a suitable groove for welding. Refer to Illustrations 88 & 89.
The single V groove joint shown is used when the crack does not extend through the full thickness of the
material being repaired. The Double V Weld joint shown is used if crack extends through full thickness of
material and is welded from both sides. Surfaces to be welded should be free from all air carbon arc slag, rust,
grease, oil, paint, or any other possible contaminates.
Preheat & Interpass Temperature
(A) Dipper lip, front, & latch keeper castings
(B) Plate structures for dipper sides, dipper back, and door structures
Minimum preheat temperatures, which are based on the base metal chemical composition and weldability, are
given in the weld parameters table located in the specific section to be welded. Refer to the ""Inspection &
Salvage by Component" " section of this document.
Castings which make up the dipper lip, front castings, and latch keeper require similar preheat interpass
temperatures. While the plate structures that make up the dipper door, side plates, and dipper back require
another set of preheat and interpass temperatures. Refer to Illustration 90 and Table 49.
Table 49
General Preheat Guidelines
Cast Structures (A) Min. Preheat Temp
204° C
(400° F)
Max Interpass Temp 315° C

(600° F)
Min. Preheat Temp 110° C

(225° F)
Plate Structures (B)
Max Interpass Temp 230° C

(450° F)
When welding with dissimilar base metals, the base metal with the higher preheat requirement governs the
preheat selection
(A) 152.4 mm (6 inch)
(B) 304.8 mm (12 inch)
(C) Salvage Cavity
(A) Infrared Thermometer
(B) Temperature indicating crayon
Salvage welding shall not be performed on any steel while the temperature of the base metal within a radius of
304.8 mm (12.00 inch) of the cavity is below normal room temperature 21.1° C (70° F). Preheating shall be
applied as required to bring the base metal up to room temperature within the 304.8 mm (12.00 inch) radius, and
the specified preheat temperature within a 152.4 mm (6.00 inch) distance of the weld cavity. Refer to Illustration
91. These temperatures must be monitored using one of the devices as shown in Illustration 92. The
temperatures must be maintained throughout welding.
Filler Metals
Flux Cored Arc Welding (FCAW) Electrodes
As long as tubular welding wires remain sealed in the original container they have a considerable shelf life.
Since the coils are packaged one-to-a-box, they should remain in their original sealed containers until a coil is
needed. When placing the new coils in the wire feeder, any partial coils which have a useful amount of wire
remaining shall be placed in a plastic bag and sealed.
All partial coils should be used up prior to opening any new coils. If only a few layers of wire remain, the coil
should be discarded. Any coil of wire which appears rusty or bent out of shape should be discarded.
Shielded Metal Arc Welding (SMAW) Electrodes
Unless properly stored and handled, low hydrogen electrodes are susceptible to moisture pick-up. To protect the
low hydrogen (crack resistant) properties, the electrodes must be treated in accordance with the following:
1. Immediately after removal from hermetically sealed containers electrodes shall be stored in ovens held at
a temperature of at least 121° C (250° F), but not more than 177° C (350° F).
Table 50
Maximum Time Permitted Out of Storage Oven Before Redrying Necessary
Electrode Time
E8018-C1 2 hours
2. Table 50 indicates the maximum length of time that low hydrogen electrodes can be out of the storage
oven before redrying is necessary:
Table 51
Redrying Times and Temperature
Electrode Temperature Time
E8018-C1 2.5 Hours

371° C (700° F)
3. If redrying is necessary electrodes shall be dried according to Table 51.
Shielding Gas
Shielding in flux cored arc welding shall be 100% CO2 and of a welding grade having a dew point of −40° C
(−40° F) or lower.
Mechanical Requirements
Table 52
Filler Metal Minimum Mechanical Properties
Elongation Charpy V-
Filler Metal
Process Tensile Strength Yield Strength in Notch
Classification
50.8 mm (2.0 inch) Requirements
27J (20 ft·lbs)
E80T1-Ni1 551.2 MPa 468.5 MPa 19 % −45.6° C

(80,000 psi) (68,000 psi) (−50° F)
E81T1-Ni2 551.2 MPa 468.5 MPa 19 % −45.6° C

(80,000 psi) (68,000 psi) (−50° F)
FCAW
E309LT-1 516.8 MPa NA 30 % NA

(75,000 psi)
High Chromium-iron alloy which produces chromium carbides in an Austenitic
Matrix. Commonly used in crushing applications where severe abrasion is
Hardfacing
experienced such as wear plates, large bucket lips, and teeth.. Typical deposit
hardness of 58-62 Rc
E8018-C1 551.2 MPa 468.5 MPa 19 % −59.4° C

(80,000 psi) (68,000 psi) (−75° F)
SMAW E309L-16 516.8 MPa NA 30 % NA

(75,000 psi)
High Chromium-iron alloy which produces chromium carbides in an Austenitic
Matrix. Commonly used in crushing applications and where severe abrasion is
Hardfacing
experienced such as wear plates, large bucket lips, and teeth.. Typical deposit
hardness of 58-62 Rc
Welding Techniques
Weld layer technique after crack excavation
Welding Technique
Welding technique (Example: the manipulation of the welding electrode and deposition pattern of the weld
metal), is important in producing a quality salvage weld.
Weld metal shall be deposited in weld beads and layers as shown in illustration 93.
Puddling or continuing to weld with the electrode nearly stationary or in a tight circular pattern shall not
be done.
The width of weld beads deposited in the vertical position of welding shall not exceed 1-1/2 times the
width shown for the flat position. Do not weld in a vertical down progression.
The rate of travel and width of weaving shall be controlled to maintain the above limits on the width of
weld beads.
Post Weld Treatments
Post Weld Treatments include the Stress Relief, Slow Cooling, and Finishing.
Immediate Slow Cooling
Example of welding blanket
Immediately after welding is complete it is recommended that the weld be covered for slow cooling to reduce
the chance of hydrogen cracking. The use of an insulated welding blanket is recommended in order to retain the
heat.
Surface Finish & Inspection

Weld repairs that do not get machined should be ground flush or shaped to match the profile of the surrounding
material of the structure. This can be done with a hand grinder and flexible sanding discs. The repair shall have
no visible defects present such as rollover, undercut, porosity, or slag inclusions. In addition, each repair shall be
inspected using one of the ""Crack Detection Methods" " listed in this document.
Stress Relief Recommendation
In order to reduce the amount of residual stresses after welding it may be necessary to perform a stress relief
heat treatment. Refer to the ""Stress Relief" " section of this document.
Stress Relief
Equipment
Example of flexible ceramic resistance heating blanket
It is suggested that a ceramic resistance type heating system is used to apply local stress relief to weld repairs.
The system should be applied to the repair area so that the heat band extends around the entire piece for a width
of at least five times the thickness of the weld throat.
The system shall be designed so that it can provide the specified hold temperature with variation not to exceed ±
3.9° C (25° F).
Automatic controlling temperature recording instruments shall be used. Thermocouples for controlling and
recording stress relieving temperature shall be attached directly to the part. Temperature readings shall be within
± 0.5% of the temperature indications of the calibration equipment.
Stress Relief Requirements
NOTICE
Do Not expose dipper liner wear material or bushings to stress relief
temperatures. These items must be removed from any areas requiring
stress relief and then reinstalled afterward.
Salvage Welds
Weld repairs to cracks or salvage welds with depths exceeding 20% of the wall thickness or 25.4 mm (1.00 inch)
whichever is smaller, or exceeds 652 mm2 (10 in2) per area welded require stress relief.
Bores
If dipper or dipper door bores do not meet the dimensional requirements of this document and require weld
build-up and re-machining, it is recommended that they are stress relieved before machining.
Stress Relief Requirements for Salvage Welds

(A) Dipper lip, front, and latch keeper castings
(B) Dipper side plates, back, and door
(D) Depth of weld repair
Table 53
Stress Relief Parameters for Crack Repair/Salvage Welds
Max allowable heating
rate above
37.8° C (100° F) per hour
315.6° C (600° F)
A (1) Hold temperature

538° C (1000° F)
Dipper Lip, Front, and Latch Keeper
Castings Hold time 1 Hour / Inch of weld repair depth (D) (2)
(1 Hour Minimum)
Force air cool from the holding
Cooling Rate temperature to below
260° C (500° F)
Max allowable heating
rate above
37.8° C (100° F) per hour
315.6° C (600° F)
B (1) Hold temperature

Side Plates 566° C (1050° F)
Dipper Back 1 Hour / Inch of weld repair depth (D) (2)
Dipper Door Hold time
(1 Hour Minimum)
Max allowable cooling
rate above
37.8° C (100° F)
315.6° C (600° F)
(1) Refer to Illustration 96
(2) For depths over 51 mm (2.0 inch) use 2 Hours + .25 Hours / Inch for each inch over 51 mm (2.0 inches)
Stress Relief Parameters for Bores
(E) Thickness/depth of weld build-up
Table 54
Stress Relief Parameters for Bore Build-up
Max allowable furnace heating rate above
315.6° C (600° F) 37.8° C (100° F) per hour
Hold temperature
565.7° C (1050° F)
1 Hour / Inch of weld repair depth (D)
Hold time
1 Hour Minimum.
Max allowable furnace cooling rate above
315.6° C (600° F) 37.8° C (100° F) per hour. Refer to Illustration 98
Profile Grinding
Definition
Profile grinding means complete grinding of the weld including toe grinding of both toes. This is done to remove
all fusion lines and provide a smooth contour to the weld face. Some general rules are as noted:
Apply only to full penetration welds - back-gouge is required.
Apply only for the length specified on the drawing or illustration.
The minimum fillet size for profile grinding is = 12.7 mm (0.50 inch).
Blend grind for a smooth transition in fillet size between the profile ground area and adjacent non-profile
ground areas.
(A) Initial size of weld before grinding.
(B) Final contour of profile ground weld.
(S) Leg size of fillet specified on drawing
(T) Tolerance for size of weld = 3.18 mm (0.125 inch)
Profile grind the entire weld face and toe grind both toes so that all fusion lines are removed. Refer to Illustration
99. When depositing the weld, the size shall be such that it meets the size specified on the drawing or illustration
(S) ± (T)
Techniques

Grinding method using burr type grinder.
(B) Angle of burr grinder 45° to weld toe line.
(C) Grinding marks perpendicular to weld toe line.
(D) Direction of travel


Alternative toe grinding method using cone shaped stone grinding.
(E) Weld toe line.
(F) Direction of grinding marks.
(G) Grinding marks perpendicular to weld toe line - 90°

(J) Face of weld
A disc type grinder can be used to grind the face of the weld.
Acceptance Criteria

(A) No Good - Unacceptable
(B) Good - Acceptable
(C) Fusion line not removed by grinding
(D) Ineffective toe grinding not into plate surface
(E) Effective toe grinding
(F) Minimum grind radius = 7.938 mm (0.3125 inch)
(G) Maximum depth of grinding below visible fusion line = 0.7938 mm (0.03125 inch)
Dipper Lip Wear Measurements

Dipper Lip
To maximize the performance and reliability of Caterpillar Electric Rope Shovel (ERS) Ground Engaging
Equipment (GET), it is essential to bring the lip as close to the original specification as possible. Generally, if
the lip is not new or in close to new condition, weld build-up and gauging of the fit surfaces will be required. If
wear material, shear blocks, or other hammerless GET components have been added, they may need to be
removed prior to gauging or measuring.
Gauge Usage

(A) Example of typical Shroud Gauge
(B) Example of typical Adapter Gauge
Obtain the correct Adapter and Shroud gauges for the dipper lip to be inspected as shown in Illustrations 105 and
106.

(C) Lip Adapter Stations (1-9)
(D) Lip Shroud Stations (1-8)
NOTICE
When applying or pushing gauge onto lip DO NOT force gauge onto lip
if there is resistance. This can distort and bend gauge out of tolerance
making it inaccurate.
Procedure
Apply the gauges as shown to determine if the dipper lip requires weld build-up.
Adapter Gauge

(E) Pin
1. Remove the pin (E) from the adapter gauge.
2. Grind off any raised areas created by material that has been displaced by the adapter movement.

(F) Leading edge
3. Place gauge on lip and push forward until the gauge contacts the leading (F) edge of the lip.

(G) Install pin
(H) Pull gauge away from lip
4. Install the pin into the top hole of the gauge, through the lip hole, and through the bottom hole of the
gauge (G), then pull the gauge away from the lip (H) .

(J & K) - Measurement locations

Multiple Measurement Locations
5. Use a feeler gauge to measure the gap between the front of the lip and the gauge. See Illustration 110 for
locations and acceptable gap conditions.
6. Lift the gauge so that gap conditions are all on the top of the lip. Measure the gap conditions (K) shown in
Illustration 110 using a feeler gauge between the front and rear fit pad areas and the adapter gauge.
Measurements should be taken in multiple sample locations as shown in Illustration 111.
7. If the gap conditions exceed 6 mm (0.24 inch), the lip will require weld build-up. Refer to ""Weld Build-
up for Adapter and Shroud Areas" " of this document.
Shroud Gauge
1. If a mounting boss is present, remove the lug locator plate (L) from the shroud gauge. This plate is only
used to check position of a mounting boss and will not be used to check lip condition. The lip must be
checked and with-in specification before checking mounting boss position.
2. Place gauge on lip and push rearward until the gauge contacts the leading edge of the lip. It may be
necessary to grind off any raised areas created by material that has been displaced during previous wear. If
a mounting boss is present, make sure the boss does not interfere with the gauge. If the boss interferes,
remove the boss from the lip.

(M) Gap between top of lip and gauge

Multiple Measurement Locations
3. Once the gauge fully contacts the leading radius on the lip, lift the gauge vertically so that the gaps
between the gauge and lip are on the top (M). Measure the gap conditions using a feeler gauge between
the front fit pad areas and the shroud gauge. If gap conditions exceed 6 mm (0.24 inch), the lip will require
weld build-up.
4. Check for gaps in the lip radius area. This area may require grinding or weld build-up to create a smooth
uniform fit between the lip and shroud. Measurements should be taken in multiple sample locations as
shown in Illustration 115.
5. Once the lip radius has been smoothed to the gauge, check the lip stabilizer width and front for gaps. If
gap conditions exceed recommended gap conditions, the stabilizer will require weld build-up.
6. Check position of the mounting boss. If the boss is already installed, proceed with Steps 7-10.
7. Install the lug locator plate back into the gauge.
8. Pull the gauge towards the front of the lip until the lug locator plate is contacting the mounting boss lug.
9. Use a feeler gauge to measure the gap between the leading edge (radius) of the lip and the gauge. If the
gap exceeds 6mm, the mounting boss lug will have to be removed and relocated.
10. See ""Lip Shroud Mounting Boss Installation Instructions" "for mounting and location instructions.
Weld Build-up for Adapter and Shroud Areas
Should areas of the lip require build-up per other sections of this document, use the following guide.
1. Remove all dirt, oil, grease, paint, rust, scale, or any other contaminants of the areas to be welded.
2. Use the appropriate gauge for the area to be welded to determine the thickness of build-up required. The
gap between the gauge and lip determine the amount of build-up required.
3. Refer to Tables 55 and 56 for welding materials and parameters to be used during build-up of the lip
Adapter and Shroud areas.
Table 55
Welding Electrodes for Build-up
Welding Electrode
Electrode
Process Diameter
SMAW 4.0 mm SMAW electrode with a deposit hardness between 28-35 Rockwell C.
(0.156 inch)
FCAW 1.6 mm FCAW electrode with a deposit hardness between 28-35 Rockwell C.
(0.062 inch)
Table 56
Welding Parameters for Build-up
Process/Electrode Amps Volts
SMAW
140-220 --
4.0 mm (0.156 inch)
FCAW
125-225 26-32
1.6 mm (0.062 inch)
Min. Preheat Temp.

204.4° C (400° F)
Max. Interpass Temp.

260° C (500° F)
Build-up Technique for Adapter Areas

(P) Order of weld build-up areas
(R) Direction of weld passes
(2A-2D) Progression of weld passes
1. Ensure the application area is clean and free of grease, rust, and moisture. Grind to clean metal if
necessary.
2. Preheat the area around where the base will be located to 204° C (400° F).
3. Build-up the rear fit pad areas and the front fit pad areas using an alternating side-to side welding process.
On the rear fit pad areas start the first weld pass at the front of one of the pads. The progression of the next
pass should be to the rear of the first pass as shown in Illustration 116 (2A-2D). Alternate applying weld
passes between the rear and front pads to reduce the chance for overheating.
4. Start the build-up of the front edge (3) at the bottom of the front surface.
5. The next weld pass should be above the first as shown in Illustration 116.
6. After the front has had the first series of weld build-up applied, confirm the location of the gauge to the
front and rear fit pad areas, or to the lug locator plate according to the ""Dipper Lip Wear Measurements"
" section of this document.
7. Weld build-up stabilizer area (4) as needed

8. Periodically use straight edges and the gauge to check the progress of the weld build-up to minimize the
amount of grinding required for proper fit-up.
9. Allow the lip edge to slow cool.
NOTICE
DO NOT leave grinding gouges on the lip surface.
10. Disc-grind the weld build-up to the desired thickness using the cage gauge as a guide. Avoid over heating
the surface with the grinder (avoid grinder burns). Blend the weld profile smooth into the lip material.
11. Slide on a new shroud or adapter and verify that it fits properly onto the lip and that the necessary
hardware can be installed. The shroud or adapter should not be forced on or allowed to bind up on the lip
surface.
Weld Build-up Areas for Shroud Areas

(P) Order of weld build-up areas
(R) Direction of weld passes
(2A-2D) Progression of weld passes
necessary.
3. Start the build-up of the front edge at the front top fit pads (1) using an alternating side-to-side welding
process.
4. On the fit pad areas, start the first weld pass at front of one of the pads. The next weld pass should be
above the first pass. Alternate applying weld passes between the left and right pads to reduce chance for
overheating. Weld build-up area as needed.
5. Periodically use straight edges and the gauge to check the progress of the weld build-up to minimize the
amount of grinding required for proper fit-up.
6. Allow the lip edge to slow cool.
NOTICE
DO NOT leave grinding gouges in the lip surface.
7. Disc-grind the weld build-up down to the desired thickness using the cage gauge as a guide. Avoid
overheating the surface with the grinder (avoid grinder burns).
8. If mounting boss is not installed, proceed to the ""Lip Shroud Mounting Boss Installation Instructions" "
section of this document. Otherwise, place shroud gauge on lip and ensure it can be fully installed.
9. Check Radius (2) with gauge to ensure gap conditions are less than 6 mm (0.24 inch).
10. Slide on a new shroud and verify that it fits properly onto the lip and that the necessary hardware can be
installed. The shroud or adapter should not be forced on or allowed to bind up on the lip surface.
11. Weld build-up stabilizer area (3) as needed.
Lip Shroud Mounting Boss Installation Instructions
Check lip shroud bosses for wear, defects, and proper location on the lip. Ensure used bosses are in good
condition without signs of wear or cracks. Ensure welds are in good condition. If wear or defects are present,
install new lip shroud bosses in the proper position according to the following instructions.
necessary.
NOTICE
Do not hammer on gauge to make it fit. Do not lift gauge from lug
locator plate.
3. Place gauge over the lip, ensuring the front of the gauge bottoms out on the front of the lip.

(L) Locator plate
4. Remove the lug locator plate (L) .
5. Insert mounting boss through the back of the gauge and push it forward until it touches gauge.
Note: The gauge should be resting flush on the top front fit pads.
Note: Do not lift the rear of gauge.

(L) Locator Plate
(M) Contact between Lug and Locator Plate
6. Install the Lug Locator plate (L) back into place.
7. PULL THE MOUNTING BOSS BACK UNTIL THE LUG MAKES CONTACT LOCATION (M)
WITH THE LUG LOCATOR PLATE (L) .

Boss tack weld locations
8. Tack weld the boss in position at 4 points onto the lip as shown in Illustration 120 using the parameters
listed in Table 57.
Table 57
Electrode
Welding Process (AWS Classification)
SMAW E8018-C1
FCAW E81T1-Ni2
GMAW ER80S-D2
Min. Preheat Temp.

204° C (400° F)
Max. Interpass Temp.

260° C (500° F)
9. Remove Lug Locator plate and remove gauge.
10. Check interpass temperature and preheat if required according to Table 57

(N) Welds
11. Weld the C-shaped fillet welds (N) at the front and back of the bossing using the parameters listed in Table
57.
12. Allow welds to slow cool before installing shroud.
Crack Detection Methods

Inspection personnel can reference ASTM E165 and E709 for further details on inspection processes.
Personnel who perform examinations in accordance with this guide shall be qualified and certified. Individuals
must be certified for Magnetic Particle Inspection at a minimum Level I in accordance with ASNT
Recommended Practice No. SNT-TC-1A or ASNT CP-189. Individuals performing Ultrasonic Testing shall be
qualified to ASNT Level II.
There are four major Inspection Methods listed in this section: Liquid Penetrant Examination, Dry Magnetic
Particle Inspection, Wet Magnetic Particle Inspection, and Ultrasonic Testing.
Crack detection methods commonly used are liquid penetrant, dry magnetic particle, wet magnetic particle, and
ultrasonic testing. There may be more than one acceptable crack detection method for the inspection of a given
part, although the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used
when inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet
Magnetic Particle Inspection is more accurate. Refer to Table ""Wet Magnetic Particle Inspection" ".
Table 58
Crack Inspection Method Advantages vs. Disadvantages
Inspection Method Advantages Disadvantages
- Least expensive
- Minimal training
- Least sensitive
Liquid Penetrant Testing (PT) - Portable
- Detects surface cracks only
- Works on nonmagnetic
material
- Works on magnetic material only
Magnetic Particle Inspection - Portable
- Less sensitive than Wet Magnetic Particle
(MPI)-Dry - Fast
Magnetic Particle Testing - More sensitive than Liquid - Requires Power for Light
(MPI)-Wet Penetrant - Works on magnetic parts only
- Detects subsurface as much - Liquid composition and agitation must be
as monitored
0.13 mm (0.005 inch)
- Most sensitive - Most expensive
Ultrasonic Testing (UT) - Detects deep material - Requires operator training and
defects certification
Liquid Penetrant Examination
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to
do the job.
Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.
Materials and Equipment Required
Refer to Tooling and Equipment Table 4 for part numbers.
Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the
surface clean.
Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with
capillary action.
Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a
contrasting background to increase the visibility of the penetrant indications.
Wire Brush: Removes dirt and paint.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
To inspect for cracks using the liquid penetrant, use the following procedures.
1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to
inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry. If there is
visible crack remove paint using paint remover or wire brush.
2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to
soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow
the area to dry thoroughly.
4. Before using Developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately 8-
12 inches away from part, apply an even, thin layer of developer over the area being inspected. A few thin
layers are a better application method than one thick layer.

Cracks found during a liquid penetrant examination.
5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show
as red lines in white developer background, refer to Illustration 126. Clean the area of application of the
developer with solvent cleaner.
Dry Magnetic Particle Inspection
This section covers dry magnetic particle inspection techniques and equipment.
Materials and Equipment Required

(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(C) Dry powder bulb.
1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to
produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast
with the background of the surface being inspected.
2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture,
grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the
form of particle color change and particle agglomeration. The degree of contamination will determine
further use of the powder.
3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System
Performance/Sensitivity) when not performing.
4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic
material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a
localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the
electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall
have a lifting force of at least 4.5 kg (10 lbs).
5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry
magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing
those particles that are evidence of indications.
6. All equipment shall be inspected at a minimum of once per year or when accuracy is questionable.
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other
contaminants.
2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
3. Simultaneously apply the dry powder using the dry powder blower.
4. Remove excess powder by lightly blowing away the dry particles.
5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad
(90°) to ensure that multiple directions of the magnetic field are created.
6. Observe particles and note if any clusters of particles appear revealing an indication.
7. Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Inspection
This section covers wet magnetic particle inspection techniques and equipment.
Materials and Equipment

(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV Lamp used in wet magnetic particle inspection process.
1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will
allow application to the test surface by spraying.
2. Concentration:
a. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and
be checked by settling volume measurements.
b. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped
centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions. Before sampling,
the suspension shall be thoroughly mixed to assure suspension of all particles, which could have
settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30
minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a
100 mL (3.40 oz) sample.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be
used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following characteristics:
Impart good wetting characteristics and good dispersion.
Minimize foaming and be non-corrosive.
Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).
Non-fluorescent, non-reactive, and odorless.
Alkalinity shall not exceed a pH of 10.5.
3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic
material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a
localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the
electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall
have a lifting force of at least 4.5 kg (10 lbs).
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any
other contaminants.
2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
3. Visually inspect for indications of discontinuities using the proper illumination.
4. Record the size and shape of any discontinuities found.
Ultrasonic Testing
Ultrasonic testing shall be performed to either the requirements of ANSI/AWS D1.1-96 Structural Welding Code
or the equivalent, applicable ISO Standards.
Copyright 1993 - 2018 Caterpillar Inc. Fri May 18 2018 09:30:02 GMT-0500 (Hora est. Pacífico, Sudamérica)
Todos los derechos reservados.
r080jvq
Red privada para licenciados del SIS.

Manual Dipper 7495 - Inspeccion en Campo OEM PDF

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18/5/2018 USE PARTS IDENTIFICATION EXPANDED MINING ER600001-UP (MACHINE)(SEBP6510 - 00) - Sistemas y componentes

Pautas de reutilización y recuperación

Electric Rope Shovel Dipper Inspection Reuse & Salvage{0374, 0599,

Electric Rope Shovel:

Information contained in this document is considered Caterpillar: Confidential Yellow.

Caterpillar Dealer Technical Communicator

Dealer Solution Network

Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

This safety alert symbol means:

Your Safety is Involved.

Tooling & Equipment

5P-3920 Rule- Steel 1

9U-7377 Metal Marking Pen 1

399-5769 Whisler 12 Shroud Gauge 1 (2)

450-1641 Whisler 10 Adapter Gauge (3)

457-1628 Upper Corner Gauge (1)

457-1629 Lower Corner Gauge (1)

385-4008 Micrometer Tool Set, External 1

222-3074 Medium Mini Die Grinder (1)

222-3076 Right Angle Die Grinder (1)

222-3077 Extended Die Grinder (1)

222-3080 Long Air Hammer (1)

223-4356 Weld Breaker (1)

236-8097 Carbide Burr (1)

1U-6825 A-Shaped Grinding Wheel (1)

4C-3770 Grinding Wheels (1)

254-5342 Flap Disc (1)

254-5319 Surface Condition Brush (1)

415-4055 Ultrasonic Tool GP (1)

349-4203 Infrared Thermometer (1)

4C-4113 Oxy - Propane Kit (1)

4C-5823 Heating Torch Handle (1)

4C-5830 Heating Torch Mixer (1)

4C-5831 Tip Tube (1)

4C-9616 Welding Blanket (1)

477-3166 (4) Portable Boring Bar (110V) (1)

477-3167 (4) Portable Boring Bar (240V) (1)

477-3189 Bore Welding System (1)

- Welding, Cutting, & Arc Gouging Equipment (1)

- Welding Electrodes/Filler Metals (5)

- Straight Edge (1)

- Temperature Indicating Crayon (1)

(D) Indicates the diameter of the bore.

(T) The overall width or thickness of bore.

Take measurements at locations (D1), (D2), and (D3).

Then take measurements at locations (D4), (D5), and (D6).

(A) Example padlock pin

(B) Straight edge

(E) Indicates the diameter of the shaft.

Take measurements at locations (E1), (E2), and (E3) .

To help prevent personal injury, follow the instructions and warnings on

Personal injury can result from flame cutting or welding on painted

Do not flame cut or weld on painted areas.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When

Note: Before inspection the following is suggested

During cleaning, do not damage machined surfaces.

Use pressurized air to dry parts.

Use appropriate thread taps to chase all threaded holes.