Base Edge Center on Fusion Buckets May Bow on Certain Medium Wheel Loaders {6001, 6101, 6801} Caterpillar

Wheel Loader

950 GC (S/N: M5K1-UP; M5T1-UP)

950M (S/N: KSA1-UP; EMB1-UP; ENE1-UP; XCJ1-UP; NHL1-UP; FTR1-UP; LCR1-UP; J1S1-UP)

962M (S/N: K881-UP; EJB1-UP; JYD1-UP; LSE1-UP; RKH1-UP; RCL1-UP; J2S1-UP; F2T1-UP)

966M (S/N: EJA1-UP; DYC1-UP; R8D1-UP; LMM1-UP; KJP1-UP; L8R1-UP; GMS1-UP)

966M Series XE (S/N: FL21-UP; P6C1-UP; B8P1-UP)

Work Tool

BUCKET (S/N: YZA1-UP; Z1A1-UP; ARN1-UP; 7NW1-UP; ANX1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

The base edge surface on fusion buckets may be bowed beyond the specified tolerance with and without coupler connected when received at dealer/customer sites with near zero-hour service. The center of the base edge deflects upward and fails to provide adequate flat surface expected. This may speed up the wear on corner GET components.

Solution

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Follow the below procedure in the event of bucket base edge deflection is found on machines listed above.

1. Record the bucket's part number and serial number. Follow safety precautions to avoid personal injury or/and damage to the part.
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   Illustration 1	g06329635
   (A) Block (B) String

2. Place the bucket on a level floor. Place two blocks (A) on either ends of the base edge. Use string (B) or a straight edge to measure the distance (D1) from the string (B) to the center portion of base edge from its top side. To find the deflection, subtract the distance (D1) from the height of the blocks (A).

   If the deflection is found to be greater than 10 mm (0.39 inch), either replace the base edge on the bucket or perform the rework on the bucket by following the procedures below.

Rework Procedure for the Existing Base Edge by Edge Straightening System

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Illustration 2	g06329681

1. Set up the straightening device in stalls with red spacer blocks. The large opening of the device faces the bucket. Ensure to maintain the hoist to run parallel with the device as shown in Illustration 2. Align the red spacer blocks in such a way that the outer sides of the blocks are at least at a distance of 25.4 mm (1.0 inch) from either side walls of the bucket. Tighten the spacer bolts until the setup is stabilized.
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   Illustration 3	g06329719

2. Install the blue color spacers stored on top of the straightening device. Align three prongs of the blue spacer with three holes on the red spacer block. Slide the pegs into the holes and set up blue spacers on top of the red spacers. As required, stack more blue spacers on the red spacer blocks if the space between the bucket and straightening device is more.
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   Illustration 4	g06329689
   Large edge straightening cylinders

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   Illustration 5	g06329704
   Small edge straightening cylinders

3. Use either small or large edge straightening cylinders. Either one works well for this process.
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   Illustration 6	g06329998
   (C) Edge straightening cylinder

4. Place the bucket in device until the cutting edges touch the device on both ends. Ensure that the hoist still remains on the bucket.

   Place the edge straightening cylinder (C) at equal space and in the middle of base edge and start to press the base edge downwards.

   Note: Slightly over-bend the edge downward because the edge will bounce back afterward. If the edge is over-bent too much, this procedure has to be reversed to make it flat.

Dealer (Cashman) Edge Straightening Procedure

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Illustration 7	g06330043

1. Place the retention bars from top of the bucket against the base edge as shown in Illustration 7.
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   Illustration 8	g06330057

2. The edge straightening system consists of a specially designed cylinder with mounting pad based on the hole pattern on the base edge. Install the mounting pad on the base edge with cylinder positioning inside on the bottom wall of the bucket. When the cylinder is pressed against the bottom wall of the bucket, the mounting pad pushes the base edge downwards. Perform this process until the bowing is completely straightened.

Replacement of Base Edge

Illustration 9	g06330120
(W1) 8 mm (0.31 inch) fillet weld over 1.5 mm (0.059 inch) square groove weld (W2) 10 mm (0.39 inch) J grove weld (Inside the bucket)

Replace the base edge with same part number. The correct base edge part number can be found on the serial number plate located on the back side of the bucket. Weld the new base edge using weld (W1) and weld (W2) from point (A) to point (B) as shown in Illustration 9.

Note: The welding material should conform to AWS A5.28-96: ER100S-G. Reference, REHS1841, "General Welding Procedures”, for additional welding procedures.

Note: Pre-camber (below level) the new base edge with a maximum value of 12 mm (0.47 inch) formed at its center portion before being welded to the bucket, Using back-up strip/plate, if needed, to ensure the gap between the bucket’s moldboard and the base edge in center portion is completely welded.

After the repair has been completed, record the final measurement to ensure that the bow has been addressed by one of the above proposed methods.