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Special Instruction
Converting Excavator Buckets from J-Series Base Edge Assemblies to the K-Series{6523,
6800, 6803, 6823}
Media Number -REHS2834-04 Publication Date -01/03/2010 Date Updated -01/03/2010

i03875718

Converting Excavator Buckets from J-Series Base Edge Assemblies

to the K-Series{6523, 6800, 6803, 6823}
SMCS - 6523; 6800; 6803; 6823

Excavator: All

Introduction
A new K-Series 2 strap adapter system is available that provides a vertical retention system that is located
at one side of the adapter nose. K-Series base edge assemblies are available to convert buckets from J300
through J700 adapter sizes. Some K adapters will fit on existing J-Series base edges. Other K adapters will
not fit without modification. Table 1 will identify the relative base edge thicknesses that each adapter will
fit.

Table 1
J Adapter Std Base Edge Thickness K Adapter Base Edge Thickness
32 mm (1.3 inch )
and
J300 K80
36 mm (1.4 inch)
36 mm (1.4 inch)

J350 K90
40 mm (1.6 inch) 40 mm (1.6 inch)

J400 K100
45 mm (1.8 inch) 45 mm (1.8 inch)

J460 K110
50 mm (2.0 inch) 60 mm (2.4 inch)

J550 K130
60 mm (2.4 inch) 70 mm (2.8 inch)

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J600 K150
70 mm (2.8 inch) 80 mm (3.1 inch)
and

80 mm (3.1 inch)

J700 K170 (1)

80 mm (3.1 inch) 90 mm (3.5 inch)
(1)
All adapters have 22.5 degree bevels except for the K170. The K170 uses a 35 degree bevel.

New K-Series base edge assemblies are also available for making conversions. The base edges that are 40
mm (1.6 inch) thick for the K90 or thicker will be butter beaded along the rear edge. Due to the large
variety of bucket sizes in the field, the base edge assemblies that are offered as parts service will not have
corner adapters welded to the base edge. The corner adapters must be welded in by the dealer or customer
after locating the proper position under the side bars. Many of the K-Series base edge assemblies are wide
enough so that the center adapters can be used at the corners requiring only minimal modification to the
lower portion of the side bar. Some base edge assemblies may not have adequate width and will require the
installation of the K-Series corner adapters.

Welding Material
Use a flux cored wire such as AWS E71T-1 with hydrogen control and with a gas shielding. E71T-1
welding wire is suitable for welding in all positions. Use welding wire with a diameter of 1.1 mm (0.043
inch) or 1.3 mm (0.051 inch)

Note: If the welds are in a position that is flat and horizontal, you can use AWS E70T-5 welding wire.

The wires should have a diffusible hydrogen specification of no more than 5 mL per 100 g of weld deposit.
Suppliers have different recommendations for the shielding gas. Generally, the use of pure carbon dioxide
is acceptable for most choices of welding wire. However, while pure carbon dioxide improves weld
penetration, a mixture of 75 percent argon and 25 percent carbon dioxide is recommended for out-of-
position welding. The mixture of argon and carbon dioxide also provides the following benefits: enhanced
arc characteristics, less welding spatter and improved bead wetting.

You may use the following low hydrogen stick electrode for all welding: AWS E7018. Since the coating of
flux on the stick electrodes will absorb moisture, the coating must be kept dry. Recondition exposed
electrodes by heating for two hours at a temperature of 260 °C (500 °F).

Suppliers of welding wire and electrodes make recommendations about power settings. When possible, use
DC reverse polarity to obtain the deepest weld penetration. This setting is called "electrode +".

If greater ductility and superior resistance to cracking are desired especially in colder climates, use the
following wire or an equivalent to either of the following: AWS E81T-Ni1 low nickel wire and AWS
E8018-C3 low hydrogen stick electrode. The wire should have a diffusible hydrogen specification of no
more than 5 mL per 100 g of weld deposit.

Preparation for Welding

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Protect yourself and others; read and understand this warning. Fumes
and gases can be dangerous to your health. Ultraviolet rays from the
weld arc can injure eyes and burn skin. Electric shock can kill.

Read and understand the manufacturer's instruction and your

employer's safety practices. Keep your head out of the fumes. Use
ventilation, exhaust at the arc, or both, to keep fumes and gases from
your breathing zone and the general area. Wear correct eye, ear and
body protection. Do not touch live electric parts.

Refer to the American National Standard Z49.1, "Safety in Welding

and Cutting" published by the American Welding Society, 2501 N.W.
7th Street, Miami, Florida 33125: OSHA Safety and Health Standards,
29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C.
20210.

Read the instructions from the supplier and understand the instructions from the supplier. 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 the following protection when you prepare the surfaces and when you
weld on the surfaces: eye protection, ear protection and body protection. Use a welding helmet with a filter
plate that is at least Shade-11. Auto darkening welding helmets eliminate the neck strain of "helmet
flipping" while greatly increasing the accuracy of electrode placement.

Before you cut on the bucket or on the weld of the bucket, the temperature of the bucket should be at least
24 °C (75 °F) to 38 °C (100 °F). Do not weld on surfaces that are exposed to fans. Do not weld on surfaces
of the bucket that are exposed to natural cool winds. Do not lay the bucket directly on the ground. Do not
lay the base edge directly on the ground.

An oxyacetylene torch or an air carbon arc torch may be used to cut an adapter away from the base edge.
The air carbon arc torch creates less heat input. This reduces the tendency for any cracks that may be in the
base edge to propagate. The gouged area is also much cleaner after using an air carbon arc torch. This
process requires less grinding.

Base Edge Assembly Replacement

Measure the dimensions of the outside edges of the bucket's base edge in order to verify the proper base
edge assembly for your bucket. Compare these dimensions to the dimensions in the following tables:

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Illustration 1 g01212922

Table 2
K80
Base Edge Dimension (A) Dimension (B) Dimension Dimension Adapters
Assembly (C) (D) Attached.

232-0022 595 mm (23.4 560 mm (22.0 250 mm (9.8 36 mm (1.42 1

inch) inch) inch) inch)

253-0132 595 mm (23.4 560 mm (22.0 250 mm (9.8 36 mm (1.42 2

inch) inch) inch) inch)

232-0023 746 mm (29.4 711 mm (28.0 250 mm (9.8 36 mm (1.42 2

inch) inch) inch) inch)

232-0024 900 mm (35.4 865 mm (34.0 250 mm (9.8 36 mm (1.42 3

inch) inch) inch) inch)

232-0025 1052 mm (41.4 1017 mm (40.0 250 mm (9.8 36 mm (1.42 3

inch) inch) inch) inch)

232-0026 1204 mm (47.4 1169 mm (46.0 250 mm (9.8 36 mm (1.42 4

inch) inch) inch) inch)

Note: For the corners, use 220-9084 Center Adapters or 220-9085 Corner Adapters and 220-9086 Corner
Adapters .

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Table 3
K90
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension Adapter
Assembly (D) Attached

232-0027 606 mm (23.8 606 mm (23.8 300 mm (11.8 40 mm (1.57 1

inch) inch) inch) inch)

232-0028 756 mm (29.8 756 mm (29.8 300 mm (11.8 40 mm (1.57 2

inch) inch) inch) inch)

232-0029 913 mm (35.9 913 mm (35.9 300 mm (11.8 40 mm (1.57 3

inch) inch) inch) inch)

232-0030 1064 mm (41.9 1064 mm (41.9 300 mm (11.8 40 mm (1.57 3

inch) inch) inch) inch)

238-3199 1212 mm (47.7 1212 mm (47.7 300 mm (11.8 40 mm (1.57 3

inch) inch) inch) inch)

232-0031 1212 mm (47.7 1212 mm (47.7 300 mm (11.8 40 mm (1.57 4

inch) inch) inch) inch)

232-0032 1354 mm (53.3 1354 mm (53.3 300 mm (11.8 40 mm (1.57 5

inch) inch) inch) inch)

Note: For the corners, use 220-9094 Center Adapters or 220-9095 Corner Adapters and 220-9096 Corner
Adapters .

Table 4
K100
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension (D) Adapter
Assembly Attached

232-0033 753 mm (29.6 709 mm (27.9 304.8 mm (12.0 44.45 mm (1.75 1

inch) inch) inch) inch)

232-0034 926 mm (36.4 882 mm (34.7 304.8 mm (12.0 44.45 mm (1.75 2

inch) inch) inch) inch)

232-0039 1064 mm (41.9 1064 mm (41.9 304.8 mm (12.0 44.45 mm (1.75 3

inch) inch) inch) inch)

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232-0035 3
1212 mm (47.7 1212 mm (47.7 304.8 mm (12.0 44.45 mm (1.75
inch) inch) inch) inch)

232-0036 1359 mm (53.5 1359 mm (53.5 304.8 mm (12.0 44.45 mm (1.75 4

inch) inch) inch) inch)

232-0037 1501 mm (59.1 1457 mm (57.4 304.8 mm (12.0 44.45 mm (1.75 5

inch) inch) inch) inch)

232-0038 1658 mm (65.3 1614 mm (63.5 304.8 mm (12.0 44.45 mm (1.75 5

inch) inch) inch) inch)

Note: For the corners, use 220-9104 Center Adapters or 220-9105 Corner Adapters and 220-9106 Corner
Adapters .

Table 5
K110
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension Adapter
Assembly (D) Attached

253-0103 751 mm (29.6 751 mm (29.6 325 mm (12.8 60 mm (2.36 1

inch) inch) inch) inch)

253-0104 903 mm (35.6 903 mm (35.6 325 mm (12.8 60 mm (2.36 1

inch) inch) inch) inch)

253-0105 1050 mm (41.3 1050 mm (41.3 325 mm (12.8 60 mm (2.36 2

inch) inch) inch) inch)

253-0106 1202 mm (47.3 1202 mm (47.3 325 mm (12.8 60 mm (2.36 3

inch) inch) inch) inch)

257-1771 (1) 1216 mm (47.9 1216 mm (47.9 400 mm (15.7 60 mm (2.36 3

inch) inch) inch) (1) inch)

253-0108 1355 mm (53.3 1355 mm (53.3 325 mm (12.8 60 mm (2.36 3

inch) inch) inch) inch)

253-0107 (1) 1369 mm (53.9 1369 mm (53.9 400 mm (15.7 60 mm (2.36 3

inch) inch) inch) (1) inch)
253-0109 4

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1507 mm (59.3 1507 mm (59.3 325 mm (12.8 60 mm (2.36

inch) inch) inch) inch)

253-0110 (1) 1527 mm (60.1 1527 mm (60.1 400 mm (15.7 60 mm (2.36 4

inch) inch) inch) (1) inch)

253-0111 1580 mm (62.2 1580 mm (62.2 325 mm (12.8 60 mm (2.36 4

inch) inch) inch) inch)

253-0112 1659 mm (65.3 1659 mm (65.3 325 mm (12.8 60 mm (2.36 3

inch) inch) inch) inch)

253-0113 1659 mm (65.3 1659 mm (65.3 325 mm (12.8 60 mm (2.36 4

inch) inch) inch) inch)

253-0114 (1) 1659 mm (65.3 1659 mm (65.3 400 mm (15.7 60 mm (2.36 4

inch) inch) inch) (1) inch)

253-0116 (1) 1701 mm (67.0 1701 mm (67.0 400 mm (15.7 60 mm (2.36 5

inch) inch) inch) (1) inch)

253-0115 1704 mm (67.1 1704 mm (67.1 325 mm (12.8 60 mm (2.36 4

inch) inch) inch) inch)

253-0117 (1) 1784 mm (70.2 1785 mm (70.2 400 mm (15.7 60 mm (2.36 5

inch) inch) inch) (1) inch)
(1)
75 mm (2.95 inch) deeper base edge

Note: For the corners, use 232-0114 Center Adapters or 232-0115 Corner Adapters and 232-0116 Corner
Adapters .

Table 6
K130
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension Adapter
Assembly (D) Attached

253-0126 1015 mm (40.0 1015 mm (40.0 380 mm (15.0 70 mm (2.75 1

inch) inch) inch) inch)

253-0127 1212 mm (47.7 1212 mm (47.7 380 mm (15.0 70 mm (2.75 2

inch) inch) inch) inch)

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253-0128 3
1356 mm (53.4 1356 mm (53.4 380 mm (15.0 70 mm (2.75
inch) inch) inch) inch)

257-1752 1535 mm (60.4 1535 mm (60.4 380 mm (15.0 70 mm (2.75 3

inch) inch) inch) inch)

257-1753 1895 mm (74.6 1895 mm (74.6 380 mm (15.0 70 mm (2.75 4

inch) inch) inch) inch)

257-1755 1957 mm (77.0 1957 mm (77.0 380 mm (15.0 70 mm (2.75 4

inch) inch) inch) inch)

Note: For the corners, use 232-0130 Center Adapters or 232-0131 Corner Adapters and 232-0132 Corner
Adapters .

Table 7
K150
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension Adapter
Assembly (D) Attached

264-2027 1753 mm (69.0 1753 mm (69.0 500 mm (19.7 80 mm (3.15 3

inch) inch) inch) inch)

264-2035 (1) 2050 mm (80.7 2050 mm (80.7 448 mm (17.6 80 mm (3.15 2

inch) inch) inch) inch)

264-2031 2087 mm (82.2 2087 mm (82.2 500 mm (19.7 80 mm (3.15 4

inch) inch) inch) inch)

* 264-2043 (2)
2220 mm (87.4 2220 mm (87.4 407.4 mm (16.0 80 mm (3.15 4
inch) inch) inch) inch)

264-2039 (2) 2250 mm (88.6 2250 mm (88.6 450 mm (17.7 80 mm (3.15 3

inch) inch) inch) inch)

264-2033 2413 mm (95.0 2413 mm (95.0 500 mm (19.7 80 mm (3.15 5

inch) inch) inch) inch)

264-2029 2430 mm (95.7 2430 mm (95.7 500 mm (19.7 80 mm (3.15 3

inch) inch) inch) inch)
264-2037 (2) 2

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2430 mm (95.7 2430 mm (95.7 450 mm (17.7 80 mm (3.15

inch) inch) inch) inch)

264-2041 (2) 2450 mm (96.5 2450 mm (96.5 475 mm (18.7 80 mm (3.15 3

inch) inch) inch) inch)

264-2045 (2) 2515 mm (99.0 2515 mm (99.0 387.3 mm (15.2 80 mm (3.15 4

inch) inch) inch) inch)
(1)
Stepped spade edge accepts 988 segments.
(2)
Stepped spade edge.

Note: For the corners, use 195-9154 Center Adapters or 195-9155 Corner Adapters and 195-9156 Corner
Adapters .

Table 8
K170
Base Edge Dimension (A) Dimension (B) Dimension (C) Dimension Adapter
Assembly (D) Attached

264-2051 (1) 2360 mm (92.9 2360 mm (92.9 482.6 mm (19.0 90 mm (3.54 4

inch) inch) inch) inch)

264-2047 (1) 2450 mm (96.5 2450 mm (96.5 475 mm (18.7 90 mm (3.54 3

inch) inch) inch) inch)

264-2049 (2) 2450 mm (96.5 2450 mm (96.5 450 mm (17.7 90 mm (3.54 3

inch) inch) inch) inch)

338-8669 (1) 2196 mm (86.5 2107.4 mm 386.5 mm (15.2 90 mm (3.54 4

inch) (83inch) inch) inch)
(1)
Stepped spade base edge.
(2)
Stepped spade base edge accepts 988 segments.

Note: K170 edges and adapters have a 35 degree bevel angle.

Note: For the corners, use 232-2170 Center Adapters or 232-2171 Corner Adapters and 232-2172 Corner
Adapters .

Determining Center or Corner Adapter Usage at J-Series Bucket

Corners
1. Measure the bucket inside side bar width (E) of the bucket.

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2. Measure the side bar thickness (F) .

3. Refer to table 9 for the K-Series size factor (G) in order to determine the minimum base edge length
required to use a center adapter at the corners.

Table 9
K Adapter Size Factor (G)

K80
100 mm (3.9 inch)

K90
117 mm (4.6 inch)

K100
117 mm (4.6 inch)

K110
142 mm (5.6 inch)

K130
160 mm (6.3 inch)

K150
192 mm (7.6 inch)

K170
220 mm (8.7 inch)

Note: (E) plus (F) plus (G) = minimum length of replacement base edge that will accept a center
adapter at the corners.

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Illustration 2 g01209285

Note: If the replacement base edge does not meet the minimum length requirement, the sidebars will need
to be modified to extend down to the base edge and the corner adapters will be used instead of the center
adapters.

Preparation of the Bucket

When the base edge is removed, a large amount of support and rigidity is lost. To keep the bucket sides and
bottom properly positioned, weld braces between the bowl and side plates as shown in Illustration 3.

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Illustration 3 g01052536

Properly support the bucket in order to prevent the bucket from rolling when the base edge is removed.

Removal of the Base Edge

Using K-series Center or Corner adapters at the Bucket Corners

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Illustration 4 g01209533

1. Properly support the base edge so that it will not fall when all of the welds are removed.

2. Cut away the welds between the base edge and bowl (A) and behind the corner adapters (B). An
oxyacetylene torch or an air carbon arc torch may be used to cut the welds. The air carbon arc torch
is preferred because it produces less heat and the air carbon arc torch leaves a cleaner surface.

3. Remove welds (C) between the side bars and the top of the corner adapters straps.

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Illustration 5 g01209717

4. Remove the old base edge assembly.

Illustration 6 g01213291

5. Position the new base edge assembly in the bucket, lining up with the bowl and the back of the side
bar. For accurate leveling of the base edge use a Plumb and Level Protractor which is calibrated in
half or quarter degree increments. The bolt pattern in the bucket upper bearing bores are located such

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that when any combination of two holes are horizontal, the base edge is also horizontal as shown in
Illustration 6 You may also wish to verify this when the old base edge is still in the bucket.

Preparing Side bars when Welding Center Adapters at the Corners

1. With the new base edge held in the correct position, place a new center adapter hard against the base
edge bevel and against the inside of the side bar. Mark the outline of the top strap on both side bar
surfaces.

2. Remove the base edge.

Illustration 7 g01209933

3. Cut along outline (H) marked on the side bars. Refer to Illustration 7 and burn a 45 degree bevel (J)
at the assembly wear plate if there is one.

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Illustration 8 g01210021

4. Cut bevels equal to approximately half the side bar thickness at the place that the side bar will be
welded to the adapters and base edge as shown in Illustration 8. When the side bars are 50 mm (1.97
inch) and 60 mm (2.36 inch) thick, make the bevels 20 mm (0.78 inch) by 45 degrees. Round the
corners at the front edge of the side bar in the place that the side bar will be welded to the adapter top
strap shown in Illustration 14.

5. Grind with a disc grinder all surfaces that are to be welded.

Base Edge Preparation with Center Adapters at the Corners

Note: Always remove paint, dirt, rust and moisture from the surface that is to be welded

1. Position the new base edge assembly up against the bowl and the bottom of the side bars.

2. Slide the new adapter into the corner position under the side bars. The front of the adapters must be
hard against the bevel of the base edge and 4 degrees outward as shown in Illustration 14. If an

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excessive amount of material was cut away from the edge of the bowl assembly during removal of
the original base edge, some adjustment to the adapter opening in the side bar may be necessary to
allow the adapter to fit properly on to the base edge.

3. Tack weld the adapters to the base edge. Move the base edge assembly away from the bowl in order
to facilitate welding the adapters. Preheating is also recommended prior to tack welding, just as with
regular welding. Tack welds on a cold surface could develop cracks. If the tack welds are not fully
melted with the covering welds, cracks could propagate from a small crack into a complete failure.

Illustration 9 g01210162

4. Weld the adapters to the base edge using the instructions in ""Center Adapter Welding Sequence" ".
Weld sizes are determined by the adapter groove size. Refer to Illustration 9.

a. (X) J groove weld = X mm

b. (Y) fillet weld height = X plus 2 mm (0.07 inch)

c. (Z) fillet weld width = X plus 2 mm (0.07 inch) × 1.25

Note: Stress in the adapter welds can be reduced by making the fillet welds with unequal legs.
The width of the weld should be at least 1.25 times wider than the height of the weld.

Center Adapter Welding Sequence

Note: Always remove paint, dirt, rust and moisture from the surfaces that are to be welded.

1. Preheat temperature of the base edge and the adapter should be 149 °C (300 °F) to 260 °C (500 °F)
and the inter-pass temperatures should not exceed 260 °C (500 °F).

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Illustration 10 g01212614

2. Begin the first J-groove weld pass at the front of the top strap weld groove. Weld one continuous
pass to the center of the back of the adapter as shown in Illustration 10.

Illustration 11 g01212621

3. Move to the other side of the top strap and begin a second weld at the front of the weld groove. Run a
continuous weld pass to the back of the adapter as shown in Illustration 11.

4. Return to the first welded side and weld another pass.

5. Continue to weld alternate sides of the top strap until the J-Groove is filled.

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6. Turn the base edge over and repeat Step 1 through Step 5 for the bottom straps.

7. Continue welding the alternate sides of the bottom straps until the J-groove fillet welds are complete.

Illustration 12 g01212642

8. Start the first fillet weld at point (K) with succeeding weld beads slightly behind the preceding layer
to produce a tapered weld start as shown in Illustration 12. The welds should be continuous. The
welds should reach the center, rear of the adapter straps as shown in Illustration 10 and Illustration
11.

9. Alternate each fillet weld pass until both sides of the adapter bottom straps are complete. Improved
fatigue life can be achieved by welding the last fillet weld pass (M) next to the outermost weld (L)
that is fused to the base edge. See Illustration 12.

10. Blend all weld toe undercuts and weld stop/starts.

11. Turn the base edge over and complete the fillet welds as directed in Step 8 through Step 10. If weld
stop/starts are required, these weld stop/starts should not occur at or near the bevel transition to the
flat surface of the base edge.

Base Edge Installation with Center Adapters at the Corners

Note: Always remove paint, dirt, rust and moisture from the surfaces that are to be welded

1. Place the base edge assembly into position in the bucket. Verify that it is level as shown in
Illustration 6 and apply tack welds between the bottom of the side bars, the base edge and on top of
the adapters. Preheat those areas to be reduce chances of cracks developing. See Step 3 in ""Base
Edge Preparation with Center Adapters at the Corners" ". Base edge to bowl welds do not require
preheating if the base edge is butter beaded.

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Illustration 13 g01210442

2. Preheat temperature of the corner adapter top strap, the base edge behind the top strap and the lower
portion of the side bars to 149 °C (300 °F) to 260 °C (500 °F) and weld the side bars to the adapters
and the base edge with (X) size bevels welds in Illustration 13. Cover the sidebars with equal leg (Y)
fillet welds, which should be at least 2 mm (0.08 inch) (X plus 2 mm) taller than the bevel welds.
Alternate welds between each side of the sidebars.

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Illustration 14 g01212643

3. The fillet welds should run from (N) to (P) between the bottom of the sidebars and the top of the
corner adapter straps. There should be no weld stop/starts near the front edge of the sidebars.

Illustration 15 g01210862

4. Blend in the adapter welds (Q) with a disc grinder at the front edge of the sidebar in Illustration 15 to
eliminate stress concentrating ridges, ripples or undercutting and round the corners as shown in
Illustration 14.

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Illustration 16 g01210878

5. If the bowl surface does not align with the base edge and the bowl is lower than the top of the base
edge, weld in a series dogs to the bowl and drive wedges under the dogs to bring the low points up
flush as shown in Illustration 16. Remove any braces near the area to be realigned.

Note: All K-series base edge assemblies other than the K80 base edge are butter beaded along the
back edge and do not require preheating when welding the base edge into the bucket bowl. The K80
base edge assemblies are not butter beaded and do not require preheating prior to welding. The ends
of all sizes of base edges are not butter beaded, but the K90 through K170 sized base edges should be
preheated when welds are applied between the sidebars and the base edges. All base edges should be
at room temperature before welding into the buckets. Base edge temperatures should not exceed 260
°C (500 °F) during welding.

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Illustration 17 g01210924

6. Apply stringer weld (R) to the base edge bevel and bowl assembly. Start at the center of the edge and
work toward the sides shown in Illustration 17.

7. Roll the bucket over and air arc the bottom side of the bowl at (S) to gain access to the bottom side of
stringer weld (R) as shown in Illustration 17. Fill in the gouged area with multiple weld passes
starting from the center and working toward the sides. If a wear plate is present, make the bevel weld
equal to the thickness of the wear plate. Apply 8 mm (0.32 inch) fillet welds between the base edge
and bowl assembly at (S) on the smaller base edges, increasing the fillet weld size up to 15 mm (0.59
inch) for the thickest base edges.

8. Roll the bucket back upright and fill in the rest of the bevel groove (R). Base edge bevels will range
from 6 to 16 mm (0.24 to 0.63 inch) depending on the base edge thickness. Start from the center and
work toward the sides. Fill in the bevel until the weld is flush with the bowl and the top of the base
edge.

Bucket Base Edge and Bowl Configurations

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Illustration 18 g01211047

1. There a several basic variations in attaching the bowl to the rear of the base edge assembly. These
variations are shown in Illustration 18. Base edge bowing and possible adapter weld cracking are
reduced when thick wear plates are attached at the rear of the base edge as shown in Illustration (V)
or when paddle plates are used with thicker base edge as shown in Illustration (W). Consider
installing a paddle plate on the bucket 1520 mm (59.84 inch) or wider and for improved stiffness, add
two to three gussets welded to the bottom of the bowl and plug welded to the paddle plate as shown
in Illustration (X) .

Preparing Sidebars when Welding Corner Adapters at the Corners

1. Perform Step 1 through Step 5 in ""Using K-series Center or Corner adapters at the Bucket Corners"
".

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Illustration 19 g01211226

2. With the new base edge in the correct position, place a corner adapter on the base edge and against
the sidebar. See Illustration 19.

3. Mark outline (HH) on the sidebar that will represent the shape of a filler plate. Start approximately
half way between the top of the corner adapter and the bottom protector pin hole or sidecutter bolt
holes.

4. Remove the corner adapter and make a template of the new filler plate shape.

5. Remove the base edge and cut away the sidebars at outline (HH) .

6. Verify that the template matches the newly cut surfaces of the sidebars.

7. Using the template, cut out two plates from T-1 or harder steel with the same thickness of the
existing sidebars.

8. Bevel the bottom of the sidebars and the bottom of the filler plates as described in Step 4 that is
shown in Illustration 8.

9. Disc grind all surfaces to be welded.

Base Edge Installation with Corner Adapters at the Corners

Note: Always remove paint, dirt, rust and moisture from the surfaces that are to be welded

1. Place the new base edge into position in the bucket. Verify that it is level as shown Illustration 6 and
apply tack welds between the bottom of the sidebars and the base edge. Preheating the base edge will
reduce the chance of the development of cracks.

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Illustration 20 g01211739

2. Position the filler plates between the sidebars and base edge and check for proper fit up. Apply
alternating bevel welds at (AA) and (BB) as shown in Illustration 20 until completed.

3. Apply a bevel weld (CC) between the base edge, filler plate and rear portion of the sidebar as shown
in Illustration 20 and 21.

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Illustration 21 g01211853

4. Mount the corner adapter hard against the base edge bevel and sidebar filler plate and weld J-grooves
(DD) and (FF) as shown in Illustration 21

5. Fill in vertical J-groove (EE) as shown in Illustration 21

6. Apply a bevel weld (GG) between the base edge, filler plate, and sidebar as shown in Illustration 21
and cover with a fillet weld tapering back from the leading edge of the base edge. The fillet weld
should be 4 to 6 mm (0.158 to 0.236 inch) taller than the bevel weld.

7. Cover J-groove weld (DD) with a fillet weld 2 to 3 mm (0.079 to 0.118 inch) larger than the width of
the J-groove weld.

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8. Cover J-groove weld (FF) with a fillet weld 4 to 8 mm (0.158 to 0.315 inch) larger than the width of
the J-groove. Begin over the J-groove weld (EE) at the front of the filler plate and continue back,
blending with sidebar bevel weld (CC) as shown in Illistration 21 Smooth fillet weld (FF) at the front
edge of the filler plate with a disc grinder to eliminate any stress concentrating ridges, ripples or
undercutting as shown in Illustration 22.

Illustration 22 g01212103

9. Weld the corner adapter bottom strap as described in the adapter welding instructions in Step 6
through Step 10 in ""Center Adapter Welding Sequence" ".

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