Procedure to Rework Loader Buckets for Use with Fusion Couplers {6001, 6129, 6434} Caterpillar

Integrated Toolcarrier

IT38H (S/N: JNJ1-UP)

IT62H (S/N: M5G1-UP)

Track-Type Loader

953K (S/N: LJT1-UP)

963D (S/N: LCS1-UP)

963K (S/N: LBL1-UP)

Wheel Loader

924H (S/N: HXC1-UP)

924K (S/N: PWR1-UP)

926M (S/N: LTE1-UP)

928HZ (S/N: CXK1-UP)

930G (S/N: TWR1-UP)

930H (S/N: DHC1-UP)

930K (S/N: RHN1-UP)

930M (S/N: KTG1-UP)

938H (S/N: MJC1-UP)

938K (S/N: SWL1-UP)

938M (S/N: J3R1-UP)

950H (S/N: K5K1-UP)

950K (S/N: R4A1-UP)

950M (S/N: EMB1-UP; FTR1-UP)

962H (S/N: K6K1-UP)

962K (S/N: X4T1-UP)

962M (S/N: EJB1-UP; F2T1-UP)

966H (S/N: A6D1-UP)

966K (S/N: TFS1-UP)

966M (S/N: KJP1-UP)

972H (S/N: A7D1-UP)

972K (S/N: Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

Work Tool

QUICK COUPLER (S/N: Y7A1-UP; Y8B1-UP)

Introduction

Reference: Special Instruction, REHS1841, "General Welding Procedures"

This Special Instruction contains the procedure to rework loader buckets for use with Fusion Couplers.

Read the information that is provided in this instruction before you begin installation of the components.

Safety

Show/hide table

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Show/hide table

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.

Show/hide table

Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Rework Procedure for 317-5562 Blank Hooks

Required Parts

Illustration 1	g03651526
(1) 317-5562 Hooks

Removal of Existing Hinge Plates

Show/hide table

Illustration 2	g01432358
Typical example of a bucket with the old hooks

Show/hide table

Illustration 3	g01432360
The cutting edge is perpendicular to the ground. (2) Old hinge plates

1. Remove the bucket from the host machine.

2. Use a suitable lifting device to position the bucket on level ground. Rotate the bucket so the cutting edge of the bucket is perpendicular to the ground. Secure the bucket with blocking. Refer to illustration 3.

3. Remove any paint or any debris from the area.
   Show/hide table

   Illustration 4	g01432635

   Show/hide table

   Illustration 5	g01432666

   Show/hide table

   Illustration 6	g01432674

4. Remove the existing hinge plates (2) from the bucket. Use a cutting torch or use an air carbon arc torch. Refer to illustrations 4 to 6.

   Note: The air carbon arc torch creates less heat input. Creating less heat reduces the tendency for any cracks that are in the plate material to propagate. The gouged area is also much cleaner after using an air carbon arc torch.

   Show/hide table

   Illustration 7	g01432691

5. Grind all surfaces smooth. Refer to illustration 7.

Creating a Profile in the Blank Hooks

Show/hide table

Illustration 8	g01432602
(1) 317-5562 Hooks (3) Gusset

1. Inspect the hooks (1).

   Note: The hooks are shipped with braces that hold the hooks in position during installation. Do not remove the braces until the installation process is complete.

   Note: A gusset (3) has been tack welded to the hooks. The gusset will be removed and used in the final assembly. An extra support plate may be placed across the hooks. Refer to illustration 8.

   Note: The blank hooks are composed of both 50 mm and 25 mm plates. The profile will be primarily in the 50 mm plate and will transition into the 25 mm plate.

   Show/hide table

   Illustration 9	g01432694

   Show/hide table

   Illustration 10	g01432697

   Show/hide table

   Illustration 11	g01439561
   (A) This reference line relates to the back of the rear skid of the bucket. (B) This lower reference line ensures that the side profile of the bucket is captured on the template.

2. Place a mark on the side plate of the bucket to establish a reference line. The reference line should be 90 degrees from the bottom of the cutting edge of the bucket. Refer to illustrations 9 to 11.
   Show/hide table

   Illustration 12	g01432712

3. Place a piece of cardboard on the reference line (B). Refer to illustration 12.
   Show/hide table

   Illustration 13	g01432717

4. Transfer the profile of the moldboard onto the template. Refer to illustration 13.
   Show/hide table

   Illustration 14	g01432727

5. Trim the template. Refer to illustration 14.
   Show/hide table

   Illustration 15	g01432835

6. Test the fit of the template against the moldboard. Refer to illustration 15.
   Show/hide table

   Illustration 16	g01432913

7. Transfer the female profile of the template to create a male template on a new piece of cardboard. Refer to illustration 16.
   Show/hide table

   Illustration 17	g01432837

8. Use the newly created male template to transfer the profile onto the hooks. Set the base of the template 90 degrees from the bottom edge of the hooks. Refer to illustration 17.

   Note: The template will. be primarily in the 50 mm plate and will transition into the 25 mm plate. Do not place the template in the 25 mm plate only.

   Show/hide table

   Illustration 18	g01439822

9. If necessary, add a lifting eye to the hooks. Use the lifting eye to control the hooks during the cutting process. Refer to illustration 18.
   Show/hide table

   Illustration 19	g01432841

10. Attach a lifting device to the hooks to secure the hooks from movement during the cutting process. Refer to illustration 19.
    Show/hide table

    Illustration 20	g01433629
    (C) Maintain a minimum of 30 mm (1.18 inch) of depth in the hinge plate. (D) Dig depth 200 ± 2 mm (7.87 ± 0.08 inch). (E) Angle in degrees. Refer to table 2. (F) Leading edge of the pocket (G) Position the pocket as close to the moldboard as possible.

11. Verify the measurements before cutting. Refer to illustration 20. Refer to table 2.
    Show/hide table

    Table 2

    Machine Model	Angle in Degrees (E)
    IT38H	23 ± 2
    IT62H	23 ± 2
    924G, 924H, 930G, 930H	25 ± 2
    924K, 930K, 938K, 926M, 930M, 938M	33 ± 2
    924GZ, 924HZ	35 ± 2
    928G, 928H	35 ± 2
    938GII, 938H	35 ± 2
    950H, 950K, 950M	38 ± 2
    953K	36 ± 2
    962H, 962K, 962M	38 ± 2
    963D, 963K	36 ± 2
    966H, 966K, 966M	40 ± 2
    972H, 972K, 972M	40 ± 2
    980K, 980M	40 ± 2

    Show/hide table

    Illustration 21	g01432846

    Show/hide table

    Illustration 22	g01432858

    Show/hide table

    Illustration 23	g01432874

12. Use a cutting torch to separate the hook from the plates. Refer to illustration 21 to 23.

Installation of the Hook

Show/hide table

Illustration 24	g01432889

1. Remove any slag from the hooks. Refer to illustration 24.
   Show/hide table

   Illustration 25	g01432903

   Show/hide table

   Illustration 26	g01432912

   Show/hide table

   Illustration 27	g01433249

2. Install the hooks onto the bucket to verify the fit. Refer to illustration 25 to 27.

   Note: Due to many variations in bucket designs, extra gusseting and support may be required.

   Show/hide table

   Illustration 28	g01433268

   Show/hide table

   Illustration 29	g01433276

   Show/hide table

   Illustration 30	g01433280

   Show/hide table

   Illustration 31	g01433309

   Show/hide table

   Illustration 32	g01433311

3. Make final adjustments to the hooks to obtain a tight fit. The gap should not exceed 4 mm (0.16 inch) between the moldboard and the hook. Refer to illustration 28 to 32.

4. Install the hooks.
   Show/hide table

   Illustration 33	g01433312

   Show/hide table

   Illustration 34	g01433313

5. Verify angle (E). Refer to illustration 20. Refer to table 2.
   Show/hide table

   Illustration 35	g01433314

   Show/hide table

   Illustration 36	g01433315

6. Verify point (F) on both sides of the hooks. Refer to illustration 20.
   Show/hide table

   Illustration 37	g01433316

7. Tack weld the hooks in place. Refer to illustration 37.

   Note: The tack weld should be at least 25 mm (1.0 inch) long. The tack welds should repeat after every 150 mm (6 inch).

   Note: Use welding material according to AWS A5.28-96: ER100S-G to perform the welding.

   Show/hide table

   Illustration 38	g01433521

   Show/hide table

   Illustration 39	g01433531

8. Center the gusset between the hooks. Weld the gusset in place. Refer to illustrations 38 and 39.

   Note: Make sure that the hooks are properly gusseted and supported to the bucket structure.

   Show/hide table

   Illustration 40	g01433548

9. Weld the hooks in place. Use an 8 mm (0.32 inch) fillet weld completely around the hooks. Refer to illustration 40.

10. Allow the welds to cool slowly to ambient temperature. Do not use forced air.
    Show/hide table

    Illustration 41	g01433554

    Show/hide table

    Illustration 42	g01433558

    Show/hide table

    Illustration 43	g01433564

11. Install the coupler to the bucket to verify the fit. Refer to illustrations 41 to 43.

    Note: The wedge should protrude through the pocket no more than 20 mm (0.79 inch). The minimum specification for wedge engagement is 6 mm (0.24 inch). Shims must be added If the wedge exceeds this measurement.

12. Paint the welded area with primer.

13. Allow the primer to dry completely.

14. Paint the welded area with a final coat of paint.

15. Allow the paint to dry completely.

Rework Procedure for 315-6309 Flat Back Hooks

Required Parts

Note: The flat back hook is a custom product that is available from Cat Work Tools. This type of hook is for attachments that have a flat mounting surface.

Illustration 44	g01581673
(1) 315-6309 Hooks

Welding Information

1. Remove the existing hinge plates from the work tool. Use a cutting torch or use an air carbon arc torch.

   Note: The air carbon arc torch creates less heat input. Creating less heat reduces the tendency for any cracks that are in the plate material to propagate. The gouged area is also much cleaner after using an air carbon arc torch.

2. Grind all surfaces smooth.

3. Inspect the hooks (1).

   Note: The hooks are shipped with braces that hold the hooks in position during installation. Do not remove the braces until the installation process is complete.

   Note: Braces have been tack welded to the hooks. The braces will be removed after assembly.

4. Install the hooks onto the work tool. Refer to dimension (D) in illustration 45.

5. Tack weld the hooks in place.

   Note: The tack weld should be at least 25 mm (1.0 inch) long. The tack welds should repeat after every 150 mm (6 inch).

   Note: Use welding material according to AWS A5.28-96: ER100S-G to perform the welding.

   Note: Make sure that the hooks are properly gusseted and supported to the structure that they are mounted to.

   Show/hide table

   Illustration 45	g01582714
   (1) 315-6309 Hooks (2) Typical example of work tool with flat back hooks (W1) 8 mm (0.32 inch) fillet weld all around (two places) (D) Minimum 200 ± 2 mm (7.87 ± 0.08 inch)

6. Weld the hooks in place. Use an 8 mm (0.32 inch) fillet weld completely around the hooks.

7. Allow the welds to cool slowly to ambient temperature. Do not use forced air.

8. Install the coupler to the work tool to verify the fit.

   Note: The wedge should protrude through the pocket no more than 20 mm (0.79 inch). Shims must be added If the wedge exceeds this measurement.

9. Paint the welded area with primer.

10. Allow the primer to dry completely.

11. Paint the welded area with a final coat of paint.

12. Allow the paint to dry completely.

Shim Installation

Shims are available through Caterpillar. Installation of these shims is necessary when wear to the mounting brackets on the bucket becomes excessive.

Illustration 46	g01439050
Location for measurement

The wedge should protrude no more than 20 mm (0.79 inch) through the pocket. Perform the following procedure to obtain the correct tolerance.

Required Parts

Welding Instructions

Show/hide table

Illustration 47	g01439209

1. Place a shim (1) in each pocket.
   Show/hide table

   Illustration 48	g01439210

2. Lower the shim beneath the pocket to provide some room for the weld.

3. Dress the weld.
   Show/hide table

   Illustration 49	g01439212

4. Test the coupler for a correct fit.