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Product:  EXCAVATOR
Model:  336D2 L EXCAVATOR ZCT00307
Configuration: 336D2 L Excavator ZCT00001-UP (MACHINE) POWERED BY C9 Engine

Special Instruction
Loader and Excavator Bucket Base Edge Assembly Welding Requirements {0679, 6001, 6101, 6102, 6103, 6104, 6110, 6112, 6120, 6122, 6138, 6503, 6523, 6530,
6800, 6801, 6823}
Media Number -REHS8015-01 Publication Date -13/05/2013 Date Updated -20/09/2017

    i07183965

Loader and Excavator Bucket Base Edge Assembly Welding Requirements

{0679, 6001, 6101, 6102, 6103, 6104, 6110, 6112, 6120, 6122, 6138, 6503, 6523, 6530,
6800, 6801, 6823}
SMCS - 0679; 6001; 6101; 6102; 6103; 6104; 6110; 6112; 6120; 6122; 6138; 6503; 6523; 6530; 6800; 6801; 6823

Backhoe Loader
All
Excavator
All
Track-Type Loader
All
Wheel Loader
All

Introduction
Read and understand the instructions from the supplier and the safety practices of your employer. Provide fresh air
circulation to the welding helmet in order to avoid any illnesses that can be caused by long-term exposure to the welding
fumes. The fresh air circulation will also remove any exhaled carbon dioxide that may be trapped by the welding helmet. Use
proper eye protection, ear protection, and body protection while preparing the surfaces and while you are welding on the
surfaces. Do not touch live electrical parts. Use a welding helmet with a filter plate that is at least Shade-11. Auto-darkening
helmets are recommended as these helmets eliminate neck-strain from "helmet flipping" while greatly increasing the
accuracy of electrode placement.

Low hour base edge and adapter weld failures occur when critical recommended welding practices are ignored or altered
during installation, replacement, or repair. Refer to the special instructions listed at the end of this discussion for welding-
specific types of adapters.

Bucket Ground Engaging Tool (GET) components such as base edges, adapters, and sidebars have chemistries and hardness
values that require special attention when welding. Ignoring cleanliness of the weld area, recommended preheating, using
improper weld wire and poor weld applications will lead to premature hydrogen embrittlement and resultant cracking
failures. The following welding principles should be followed to ensure that maximum component durability is attainable:

Clean welding surfaces

Use of low hydrogen welding consumables

Proper preheating

Maintaining inter-pass temperatures

Slow cooling after welding is completed

Cleanliness:

Areas that will be subject to welding must be free of paint, rust, grease, oil, scale, and slag. Contamination by these
components can cause weld cracking, weld porosity and lower weld strength.

Low hydrogen weld consumables

Using low hydrogen weld consumables such as E7018 stick electrodes, E71T-1 or E70T-5 wire is important to prevent
cracking due to hydrogen embrittlement. These low hydrogen weld consumables should have a diffusible hydrogen
rating of no more than 5 ml/100 grams of weld deposit. These help to prevent hydrogen embrittlement by reducing the
amount of hydrogen that is absorbed into the weld.

Proper preheat temperature

Applying the proper amount of preheat before welding is critical to ensuring a good weld. Preheat helps to prevent
distortion of the part due to uneven heating and helps welding by requiring less heat input from the welder. Preheating
is critical on larger parts, where the large mass can rapidly remove heat from the welding area. Preheat an area on both
sides of each adapter that is at least twice the thickness of the base edge to 190 – 232 °C (375 – 450 °F). A more uniform
heat application can be obtained if the preheating is applied on the side opposite of the side to be weld.

Maintaining interpass-temperature
 As with preheating, maintaining an even temperature distribution while welding can help prevent distortion and
improve weld quality. Inter-pass temperatures should be monitored and kept in the same temperature range as
preheating of 190 – 232 °C (375 – 450 °F). Care should be taken with large parts. Large parts can take longer to get up to
temperature during preheat and may hold more heat once the parts are hot

Slow cooling parts after welding

After welding is completed, the parts should be allowed to slow cool to prevent distortion and cracking. Slow cooling
helps prevent distortion by eliminating uneven temperature distributions and allows internal stresses developed by
weld shrinkage to dissipate. Additionally, slow cooling the parts gives a greater amount of time for hydrogen to escape
from the steel, which helps to prevent hydrogen embrittlement. All welded components should be kept out of cool
ambient air and drafts caused by fans, which can increase the cooling rate. Thermal blankets can also be used to ensure
slow cooling.

Terms used:

Hydrogen embrittlement: A failure mode of steels caused by the introduction of hydrogen gasses into the steel at high
temperatures, such as when welding. Hydrogen can be introduced due to the presence of moisture, high humidity, or
incorrect weld consumables. The hydrogen infiltrates the steel, creating internal stresses, which lowers the strength and
ductility of the steel.

Possible cracking from hydrogen embrittlement is shown in Illustration 1.

Illustration 1 g03365258
Hydrogen Embrittlement
(A) Toe crack
(B) Under bead crack
(C) Heat Affected Zone

Adapter and Base Edge Weld

Illustration 2 g03365376
Typical Location - Start of Cracking Failure
Illustration 3 g03365377
FEA Analysis Showing Stress Hot Spot
Typical representation of stress distribution at an adapter bottom strap/weld/base edge from a vertical down load on a bucket tip
(1) Base edge
(2) Lowest stress area
(3) Highest stress area
(4) Adapter

Most base edge failures start at the front of the adapter to base edge weld similar to Illustration 2. These failures can be found
at either the top or bottom strap weld start locations. Illustration 3 shows a computer Finite Element Analysis (FEA) of typical
base edge loading through the adapter and on to the base edge. This FEA reveals that the highest stresses are concentrated at
the start of the adapter to base edge weld. Therefore, taking all possible steps to ensure that the weld start is of the highest
quality is imperative. When following the welding principles previously discussed, the actual process of applying the welds is
also important.

Weld Applications

Illustration 4 g03365408
Crack caused by lack of penetration

Illustration 5 g03365409
Crack caused by blunt profile

Illustration 6 g03365412
Crack caused by cold weld and lack of penetration
Illustration 7 g03365413
Crack caused by lack of penetration

A blunt profile at the adapter weld start will hasten fatigue failure, as will cold welds and lack of penetration into the parent
metal. Refer to Illustrations 4, 5, 6, and 7.

Illustration 8 g03365516
Ideal weld starts

To reduce the effects of stress at this location, welding should start with an adequately fused first pass application. Follow this
weld by others that are indexed in steps back from the first weld. Refer to Illustration 8.

Illustration 9 g03365517
Probable crack initiation site from undercut weld toes
(D) Parent metal
(E) Undercut or cold lap weld

Good fusion at the toe of the welds is also needed to reduce the chance of failures developing from undercutting at the weld
toes. Refer to Illustration 9.
Illustration 10 g03365587
Well Applied Welds

A weld with good profile attributes, as seen in Illustration 10, shows an ideal weld application similar to the one in Illustration
8 . These welds are tapered back from the start and adequately fused into the parent metal. There is also good fusion between
the additional weld passes.

Illustration 11 g03365607
Crack due to improper weld sequence

Illustration 12 g03365609
Crack due to improper weld sequence
Illustration 13 g03365611
Alternating Weld Passes

Alternate all groove welds and fillet welds. As welds cool, the welds develop a great deal of internal stress from shrinkage.
So much so, that the adapter straps can crack due to an improper weld sequence. Refer to Illustration 11 and Illustration 12.

This problem occurs when multiple weld passes are applied to one side of an adapter strap before any weld is applied to the
other side. The first side welds shrink, pulling down on that side of the adapter. When the welds are then applied to the other
side, the welds start to cool and shrink. The internal stress then can become too great for the adapter and the adapter will
crack. Always alternate all weld applications from side to side on both top and bottom straps as shown in Illustration 13.

Base Edge/Adapter Strap Gaps

Illustration 14 g03365644
Soft wire spacers
(F) 2.3 - 3 mm (0.09 - 0.12 inch) Soft wire spacers

Dimensional tolerances between adapters and base edges may result in a large gap between an adapter strap and a base edge.
This gap is caused when the opposite strap of the adapter is positioned hard against the base edge. The larger gap may create
difficulty applying a high-quality first-pass weld. Refer to Illustration 14. Use 2.3 - 3 mm (0.09 - 0.12 inch) diameter soft iron
wire as a spacer under either the top strap or bottom strap to equalize the bottom and top strap gaps. As the welds cool and
start to shrink, the soft wire spacers also compress slightly. This compression reduces the normal stress that would occur if the
strap was hard against the base edge. Begin welding on the adapter strap that has the wire spacers under it. The use of wire
spacers also applies to top strap and single strap adapters.

Improving Weld Toe Quality

Illustration 15 g03365645
Undercut/Cold Lap Weld

Illustration 16 g03365646
Poor fusion between welds and slight undercutting at edge of adapter

Refer to Illustration 15. What appears to be a crack at the toe of the weld on a newly welded component, may have developed
from something else. What appears to be a crack may have developed from one or more of the following:

Undercut weld

Cold lap weld

Trapped slag

Trapped hydrogen

Refer to Illustration 16. Though the weld appears to follow some of these requirements, there is a lack of good fusion between
welds. This weld has poor fusion between welds at the weld starts, and slight undercutting at the base edge and adapter. With
many high bucket loading cycles, a crack will eventually start at one of these locations.

The examples in Illustration 15 and Illustration 16, though the examples appear to have minor weld imperfections, could
develop into a major cracking situation. However, these imperfections often can be removed by grinding the weld toe to
produce a smooth concave profile.

Illustration 17 g03365647
De-burring Tool
Illustration 18 g03365648
Toe grinding (blending) the toe weld
(AA) Adapter weld
(BB) Base edge
(CC) Toe of weld
(DD) Remove a portion of the toe of the weld. 0.5 - 1.0 mm (0.02 - 0.04 inch)
(EE) Grind the toe of the weld with a 12.7 mm (0.50 inch) deburring tool.

A cone grinder or rotary de-burring tool, shown in Illustration 17 can be used to produce a smooth concave profile as shown
in Illustration 18. Toe grinding, besides removing minor imperfections, will improve fatigue strength of the weldment by 30%.
Care should be taken not to overheat the ground surface until the surface becomes discolored. Avoid leaving deep grinding
marks that can act as stress concentrators.

Verify with dye check that the ground surface is free of imperfections. If the imperfection was a crack, ensure that the
crack has been removed completely and does not go any deeper.

Illustration 19 g03365649
TIG toe welding
(G) Weld metal
(H) Molten weld pool
(J) Base metal
(K) Arc
(L) Gas Shielding

Illustration 20 g03365650
TIG welding repairs
(M) TIG weld with filler wire
(N) Remelted toe with TIG process

Another method to reduce local stress concentration at the toe of the weld is by TIG dressing. TIG dressing is a method of
remelting the toe area and producing a more generous weld toe radius. Refer to Illustration 19 and item (N) in Illustration 20.
With TIG welding, poor overlapping weld starts can also be improved by remelting the welds and filling with additional wire.
This technique is shown by item (M) in Illustration 20. The areas must be preheated before any TIG welding. As most base
edge failures usually begin at the front of the base edge, toe grinding or TIG dressing need only be applied to the following
area:

Only the first few inches of weld start, and up to the base edge bevel transition to the flat surface

Illustration 21 g03365651
TIG welded toe

Refer to Illustration 21. Rounded adapter straps that are welded at the rear should also be considered for toe grinding or TIG
welding.

Sidebar/Corner Adapter Welds

Illustration 22 g03366556
Rough sidebar weld

Illustration 23 g03366557
Example of a sidebar weld that has been ground with a disc grinder

Another area of potential crack initiation and corner adapter failure is at the sidebar. Since the top of the adapters are solidly
attached to the sidebars, the straps cannot flex with the base edge like the center adapters do. Therefore, stresses are higher at
the corner adapter location. Irregular or poorly blended welds at the sidebar, shown in Illustration 22, cause bucket corner
loading forces to concentrate at this corner joint. The concentration of loading forces at this corner joint can become great
enough to initiate a crack and ultimately lead to adapter failure or sidebar weld failure. These stresses can be reduced by
blending the welds between the front of the sidebar and top of the strap as shown in Illustration 23.
J-Series Adapter Strap Tail Welds

Illustration 24 g03366558
Example of cracks starting at the rear of tail welds propagating in either of two directions

Illustration 25 g03366559
Example of a J-Series completed tail weld

The J-Series adapter strap tail welds are another area susceptible to cracking when the bucket is subject to high loads.
Feathering tail welds extending out past the back of the adapter strap may have poor penetration into the adapter. This poor
penetration into the adapter may result in a discontinuity that acts like a stress concentrator. With base edge flexing, a crack
will start at the back and work across the weld. The crack can either run down along the weld or propagate across the weld
and into the base edge. An example is shown in Illustration 24.

Additional weld should be applied against the original tapering fillet weld to eliminate any chance of poor weld fusion at the
rear of the adapter. Illustration 25 is an example of a properly completed tail weld.

Points to Remember
1. Clean the surfaces to be welded.

2. Remove and eliminate moisture sources.

3. Use low hydrogen weld consumables.

4. Preheat, preheat, preheat, maintain inter-pass temperature.

5. Apply multiple weld passes:

a. Stepped back or tapered weld starts.

b. Remove impurities after each weld pass.

c. Alternate welds side to side.

d. Toe grind or TIG weld suspicious weld toes.

e. Blend welds between front of sidebar and adapter.

6. Slow cool.

References to Adapter Welding Articles

Special Instruction, REHS0597, "Recommendations for Welding 2-strap Bucket Adapters to Base Edges"

Special Instruction, REHS2084, "Converting Buckets from J-series to K-series – All excavators"

Special Instruction, REHS2834, "Converting Straight Edge Buckets From J-Series Base Edge Assemblies to The K-Series (All
Excavators)"

Special Instruction, REHS4127, "Instructions For Welding the K-Series Adapters (All Wheel Loaders)"
 Service Magazine, SEPD0891, "Maximum temperature For Welding K-Series Adapters"

Service Magazine, SEPD1061, "25° Bevel For Abrasion Adapter Edge"

Special Instruction, REHS7722, "398-6784 Recommended J Series Two Strap Adapter Welding Sequence"

Special Instruction, REHS7723, "398-6786 Recommended J Series Flush Mount/Abrasion Adapter Welding Sequence"

Special Instruction, REHS7724, "256-2928 Recommended K Series Two Strap Adapter Welding Sequence"

Special Instruction, REHS7725, "256-2930 Recommended K Series Flush Mount/Abrasion Adapter Welding Sequence"

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