Installation Procedure for the Material Handling Slip-On Buckets on Certain Logging Forks {0679, 6001, 6101, 6103, 6104, 6113, 6114, 6123, 6405} Caterpillar

Wheel Loader

938K (S/N: REP1-UP)

938M (S/N: J3R1-UP)

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

950K OEM (S/N: DPT1-UP)

950M (S/N: ENE1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

962M (S/N: JYD1-UP; LSE1-UP)

966K (S/N: PBG1-UP; TFS1-UP)

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

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

972K (S/N: PEM1-UP; Z4W1-UP)

972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; M8W1-UP)

972M Series XE (S/N: M5S1-UP; EDW1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

980M (S/N: MGD1-UP; KRS1-UP; N8T1-UP)

Work Tool

BUCKET (S/N: 7NW1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference: Service Guide, SEBD0512, "Caterpillar Service Welding Guide"

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

Safety Section

Illustration 1	g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.

Welding Requirements

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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

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to Special Instruction, REHS1841, "General Welding Procedures". Refer to the Illustrations in this Special Instruction for welding symbols and specifications.

Use AWS E7018 Electrodes or equivalent electrodes to weld the hooks to the work tool.

All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics may vary greatly depending on the following conditions:

• Electrode diameter

• Shielding gas

• Welding current

• Plate thickness

The following items also affect the welds:

• Geometry of the welded joints

• Surface conditions

• Composition of the base metal and of the electrode

A root pass should be applied before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

For more welding information, consult the Caterpillar Service Welding Guide , SEBD0512.

Preparing the Metal for Welding

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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.

All grease, water, paint, rust, dirt and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove paint, rust, dirt and scale with a wire brush or by buffing or grinding. Shot blasting all work areas will also remove foreign material.

Remove any oil or grease with a Caterpillar approved solvent.

List of Compatible Buckets and Forks

Installation Procedure and Parts List

390-6753 Slip-On Material Bucket

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Illustration 2	g06186513
Slide forks into the 390-6753 Slip-On Material Bucket with parts in area (A) attached. (2) 4F-0255 Pin (6) 390-6869 Ear Plates (9) 2J-8937 Pin (11) 3B-4626 Cotter Pin (13) 526-9463 Plate

1. Attach the parts listed in area (A) to the rear of the bucket. Then insert the forks as shown.

   Note: Be sure to slightly pick up the bucket and tilt back to ensure that there are no gaps between the bucket and forks.

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   Illustration 3	g06186515
   Rear center view of the 390-6753 Slip-On Material Bucket. (B) 96 ± 4 mm (3.8 ± 0.2 inch) (C) 48 ± 2 mm (1.8 ± 0.1 inch)

2. Center the bucket on the forks and tack weld the two Ear Plates in place on both sides.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

3. Set the bucket on the ground, remove the pins, and slide out the forks.
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   Illustration 4	g06141597
   Close up of area D.

4. Next, weld the ear plates on both sides to the fork frame using an 8 mm filet weld as shown.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

5. Allow welded area to cool. Prepare the welded area for paint application.

6. Apply the rust prevention coat and the finish coat to the work area that has been completed. Use Caterpillar approved paint.
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   Illustration 5	g06141611
   Assembled view of the 390-6753 Slip-On Material Bucket.

7. Slide forks into bucket and secure to the fork frame with pin.

510-9841 Slip-On Material Bucket

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Illustration 6	g06142106
Slide forks into the 510-9841 Slip-On Material Bucket with parts in area (E) attached. (3) 184-5306 Pin As (4) 267-4572 Ear Plate (10) 6V-5684 Bolt (11) 6V-7687 Locknut

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Illustration 7	g06142111
Position the top of the tine to make contact with the bucket pocket plate.

1. Attach the parts listed in area (E) to the rear of the bucket. Then insert the forks as shown.

   Note: Be sure to slightly pick up the bucket and tilt back to ensure that there are no gaps between the bucket and forks.

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   Illustration 8	g06142118
   Rear center view of the 510-9841 Slip-On Material Bucket (F) 650 mm (25.6 inch) (G) 48 ± 2 mm (1.8 ± 0.1 inch)

2. Center the bucket on the forks and tack weld the four Ear Plates in place on both sides.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

3. Set the bucket on the ground, remove the pins, and slide out the forks.
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   Illustration 9	g06142534
   Close up of area H.

4. Next, weld the ear plates on both sides to the fork frame using an 8 mm filet weld as shown.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

5. Allow welded area to cool. Prepare the welded area for paint application.

6. Apply the rust prevention coat and the finish coat to the work area that has been completed. Use Caterpillar approved paint.
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   Illustration 10	g06142557
   Assembled view of the 510-9841 Slip-On Material Bucket.

7. Slide forks into bucket and secure to the fork frame with pins.

522-4941 Slip-On Material Bucket

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Illustration 11	g06186551
Slide forks into the 522-4941 Slip-On Material Bucket with parts in area (J) attached. (1) 3B-4626 Cotter Pin (2) 4F-0255 Pin (4) 390-6869 Ear Plates (8) 2J-8937 Pin

1. Attach the parts listed in area (J) to the rear of the bucket. Then insert the forks as shown.

   Note: Be sure to slightly pick up the bucket and tilt back to ensure that there are no gaps between the bucket and forks.

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   Illustration 12	g06186597
   Rear center view of the 522-4941 Slip-On Material Bucket (K) 48 ± 2 mm (1.8 ± 0.1 inch) (L) 96 ± 4 mm (3.8 ± 0.2 inch) (M) 407 mm (16 inch) (N) 292 mm (11 inch)

2. Center the bucket on the forks and tack weld the four Ear Plates in place on both sides.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

3. Set the bucket on the ground, remove the pins, and slide the forks out.
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   Illustration 13	g06186618
   Close up of area P.

4. Next, weld the four ear plates on both sides to the fork frame using an 8 mm filet weld as shown.

   Note: Ear plates can be modified as needed to level the bucket and line up with the pin holes.

   Note: Do not weld the ends of the plates.

5. Allow welded area to cool. Prepare the welded area for paint application.

6. Apply the rust prevention coat and the finish coat to the work area that has been completed. Use Caterpillar approved paint.
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   Illustration 14	g06186629
   Assembled view of the 522-4941 Slip-On Material Bucket.

7. Slide forks into bucket and secure to the fork frame with pins.