Balde Cargador 992K

19/12/2019 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine(SEBP4140 - 50) - Sistemas y componentes
Pantalla anterior
Bienvenido: cr120jxa
Producto: WHEEL LOADER
Modelo: 992K WHEEL LOADER H4C00382
Configuración: 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY
C32 Engine
Instrucción Especial
Rework Procedure for Weld Cracks on a 294-8980 Rock Bucket Gp for the 992K Wheel Loader{0679,
6101, 6102, 6820}
Número de medio -REHS5137-02 Fecha de publicación -26/11/2013 Fecha de actualización -26/11/2013
i05571910
Rework Procedure for Weld Cracks on a 294-8980 Rock Bucket Gp for

the 992K Wheel Loader{0679, 6101, 6102, 6820}
SMCS - 0679; 6101; 6102; 6820
Wheel Loader:
992K (S/N: H4C1-UP)
Introduction
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"
ReferenceSpecial Instruction, REHS4127, "Instructions for Welding the K Series Adapters"
This Special Instruction contains the rework procedures that are needed to update the paddle plate design for the
294-8980 Rock Bucket Gp .
This Special Instruction will cover the following:
Removal of the existing paddle plate and adjacent components
Installation of a new paddle plate and adjacent components
Installation of a new shell radius liner
Adapter weld inspection and repair. See the topic ""Adapter Welding" " in ""Appendix A" " for the weld
application procedure.
Checking and remachining of the B-pin bore
The sequence of steps in this Special Instruction is designed to protect the hinge plates. The sequence of steps also
provides support to limit warping from heat during the cutting and rewelding processes. Support bars should be
welded between the hinge plates to maintain the dimensional relationship. If the hinge width/bores are out of
specification after the rework is complete, a machining operation will be required before reinstallation of the
bucket. See the topic ""Hinge Location and Machining Dimensions" " in ""Appendix B" " for the recommended
support bar location and machining dimensions.
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The list of components provided includes replacement parts that may be required if damage occurs during weld
removal. Use caution in order to salvage components and replace only as needed.
Inspect all welds for cracking or damage during the disassembly process. If a weld is damaged, document the weld
location, weld size and take a photograph.
Use 1.3 mm or 1/16 inch diameter weld wire for all welds.
Safety
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
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.
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.
Required Parts
Refer to Table 1 for the parts required to update the 294-8980 Rock Bucket Gp . Refer to Illustration 2 for part
locations and Illustration 2 for part illustrations.
Table 1
Replaced by
Current Parts
Parts (1)
Item Part Qty Part Qty

Part Description Change Description
Number Number
Wear Plate
1 283-1925 1 356-6377 1 New Design Part
(Bottom Center)
Wear Plate
2 316-5889 1 356-6376 1 New Design Part
(Bottom Rear)
Plate
3 310-9004 1 356-6383 1 (One-Bend) New Design Part
Right-Hand
Plate
4 310-9005 1 356-6382 1 (One-Bend) New Design Part
Left-Hand
Plate
5 310-9033 1 356-6375 1 New Design Part
(Paddle)
Not Replaced - Protect part from damage No Change - Reference
6 Shell
during rework Only
Plate Existing Design -
7 316-5866 2 316-5866 2
(Wing) Replacement Part

8 Side Plate As
during rework Only

9 310-8981 2 310-8981 2
(Gusset) Replacement Part
10 0 356-6379 2 Wear Plate New Design Part

(Shell)
Wear Plate
11 0 356-6378 2 (Bottom Side) New Design Part
Right-Hand/Left-Hand

12 Hinge
during rework Only
13 310-9097 2 310-9097 2
(Dump Stop Cover) Replacement Part
Plate As Existing Design -

14 316-5868 2 316-5868 2
(Dump Stop) Replacement Part

15 310-8998 1 310-8998 1
(Left Heel) Replacement Part

16 310-8999 1 310-8999 1
(Center Heel) Replacement Part
Plate Existing design -
17 310-8997 1 310-8997 1
(Right Heel) Replacement part

18 316-5893 1 316-5893 1
(Mid) Replacement Part

19 Edge As
during rework Only

20 316-5894 6 343-2125 6
(Wedge) Replacement Part
Strip
Existing Design -
21 316-5897 1 316-5897 1 (Edge Backup)
Replacement Part
Optional
Wear Plate
(Floor Liner) Existing Design -
22 310-9028 1 310-9028 1
If Existing Part Is Damaged Replacement Part
Insert
N/A Existing Design -
282-9964 2 282-9964 2 If Hinge Bore Machining
Replacement Part
Required
(1) This column represents one set of parts required to update one 294-8980 Rock Bucket Gp .
Part Identification
Illustration 1 g03539578
Refer to Table 1 for a list of the parts.
New Design Parts:
(1) 356-6377 Wear Plate (Bottom Center)
(2) 356-6376 Wear Plate (Bottom Rear)
(3) 356-6383 Plate (One-Bend)
(5) 356-6375 Plate (Paddle)
(10) 356-6379 Wear Plate (Shell)
(11) 356-6378 Wear Plate (Bottom Side)
Refer to Table 1 for a list of the parts. Parts are not shown to scale.
Rework Procedure
Before Rework
After Rework
General Bucket Disassembly Notes
Note: Do NOT proceed without reviewing first.
(A) Support bar (Approximately 75 X 20 X 1600 mm steel bar 2 pieces welded perpendicular orientation)
(B) Support bar (Approximately 75 X 20 X 4572 mm steel bar or similar)
1. Install support bars (A) and (B) as shown before disassembly of bucket components. Refer to Illustrations 5
and 6.
(C) Tie bar (Install two pieces 75 X 75 X 16t angle iron (or similar) across hinge plates as shown. Length of each tie bar is
approximately 960 mm (37.8 inch))
(D) Check B-pin alignment with the fixture before installing support bars (see ""Appendix B" ").
2. Weld two tie bars (C) to each hinge plate. Refer to Illustration 7.
(12) Hinge (Inside and Outside surfaces)
(12) Hinge (Bottom surfaces)
(6) Shell (Bottom surfaces)
1. Review the locations of the surfaces shown in Illustrations 8, 9 and 10. Use caution when cutting parts
connected to these surfaces. Damage to these surfaces may result in premature failure of the bucket
structure. Any damage will need to be weld repaired and ground flush before new components are installed.
Bucket Position for Paddle Plate Rework
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Prior to welding, remove the bucket from the machine.
Position the bucket as shown to provide access to areas indicated by the arrows (see Illustrations 12 and 11).
Bottom Wear Plate and Plug Weld Removal
1. Remove the bucket from the machine. Confirm B-pin dimensions using the checking tools. See ""Appendix
B" ".
2. Install the hinge support bars as shown in Illustration 7.
3. Position the bucket so that paddle plate (5) faces upward as shown in Illustrations 11 and 12.
4. Use carbon arc gouging to remove weld from point (A) to (B) and from point (C) to (D). Remove the weld
between bottom center wear plate (1) and paddle plate (5) .
5. Remove the weld from five slots (E) and remove bottom center wear plate (1) from the bucket.
6. Remove the weld from the four slots (J). No parts will be removed from the bucket following this step.
7. Remove the weld from the six slots (K). No parts will be removed from the bucket following this step.
Note: Confirm 12.0 mm (0.47 inch) fillet weld size in slots (K). Document and photograph if the welds are
undersized or cracked.
One-Bend Plate Removal
View of Section A-A from Illustration 16
One-Bend Plate weld (left-hand side shown)
(A) Remove 16 mm (0.6 inch) fillet weld
(B) Remove 16 X 12 mm (0.6 X 0.5 inch) filler weld
1. Remove the weld from point (L) to (M) between one-bend plate (3) and shell (6). Use caution when you
remove the weld in order to prevent damage to shell (6). Excess weld remaining on shell (6) will be ground
flush before installation of the new one-bend plate (3). See the view of Section A-A in Illustration 16 for
weld detail.
2. Remove the weld from point (L) to (N) between wing plate (7), one-bend plate (3), and paddle plate (5).
Damage to paddle plate (5) and wing plate (7) is acceptable because these plates will be replaced during
reassembly.
3. Remove the weld from point (M) to (P). Use caution when you remove the weld in order to prevent damage
to side plate assembly (8). Excess weld remaining on side plate assembly (8) will be ground flush before
reassembly.
4. (Optional) Remove the weld from point (N) to (P) between one-bend plate (3) and paddle plate (5). Damage
to paddle plate (5) is acceptable because this plate will be replaced during reassembly. See the view of
Section A-A in Illustration 16 for weld detail. (This step is not required since this part will be removed with
paddle plate (5) ).
5. (Optional) Remove one-bend plate (3) from the bucket.
6. Complete Steps 1 through 5 for both Left-Hand and Right-Hand sides of the bucket.
Hinge Gusset and Plate Removal
1. Remove the weld from point (R) to (S) between gusset plate (9) and shell (6). Use caution when you remove
the weld to prevent damage to shell (6). Excess weld remaining will be ground flush before reassembly
2. Remove the weld from point (R) to (U) between gusset plate (9) and hinge (12). Use caution when removing
weld to prevent damage to hinge (12). Excess weld remaining will be ground flush before reassembly.
3. Remove the weld from point (S) to (T) to (U). Damage to gusset plate (9), wing plate (7), and right heel
plate (17) is acceptable because these parts will be replaced during reassembly.
4. Remove gusset plate (9) from the bucket. Complete Steps 1 through 4 for both Left-Hand and Right-Hand
sides of the bucket.
5. Remove the weld from point (V) to (W) between wing plate (7) and shell (6). Use caution when removing
the weld in order to prevent damage to shell (6). Excess weld remaining will be ground flush before
reassembly.
6. Remove the weld from point (V) to (Y) between wing plate (7) and hinge (12). Use caution when you weld
to prevent damage to hinge (12). Excess weld remaining will be ground flush before reassembly.
7. Remove the weld from point (X) to (Y). Damage to right heel plate (17) and paddle plate (5) is acceptable
because these parts will be replaced during reassembly.
8. Remove wing plate (7) from the bucket. Complete Steps 5 through 8 for both Left-Hand and Right-Hand
sides of the bucket.
Dump Stop Cover Removal
1. Remove the weld from point (AA) to (BB) between dump stop cover plate (13) and shell (6). Use caution
when you remove the weld in order to prevent damage to shell (6). Excess weld that remains on shell (6)
will be ground flush before installation of replacement dump stop cover plate (13) .
2. Remove the weld from point (CC) to (DD) between dump stop cover plate (13) and dump stop plate
assembly (14). Damage to dump stop plate assembly (14) is acceptable because this plate assembly will be
replaced during reassembly.
3. Remove the weld from point (AA) to (CC) and from (BB) to (DD). Use caution when removing the weld in
order to prevent damage to hinge (12) and shell (6). Excess weld remaining on shell (6) and hinge (12) will
be ground flush before installation of replacement dump stop cover plate (13) .
4. Remove dump stop cover plate (13) from the bucket.
Dump Stop Plate Assembly Removal
1. Remove the weld from point (EE) to (GG). Remove the weld from point (FF) to point (HH) between dump
stop plate assembly (14) and hinge (12). Use caution when you remove the weld to prevent damage to hinge
(12). Excess weld remaining will be ground flush before reassembly.
2. Remove the weld from point (GG) to (HH). Damage to paddle plate (5) is acceptable because this part will
be replaced during reassembly.
3. Remove dump stop plate assembly (14) from the bucket.
Note: Plug welds between dump stop plate assembly (14) and paddle plate (5) plug welds have already been
removed in Step 6 in the ""Bottom Wear Plate and Plug Weld Removal" " section.
Heel Plate Removal
1. Remove the weld from point (JJ) to (KK) between right heel plate (17) and paddle plate (5). Repeat similar
weld removal for center heel plate (16) and left heel plate (15). Damage to paddle plate (5) is acceptable
because this part will be replaced during reassembly.
2. Remove the weld from point (LL) to (MM) between left heel plate (15) and hinge (12). Repeat similar weld
removal (total of four times) for center heel plate (16) and right heel plate (17). Use caution when you
remove the weld to prevent damage to hinges (12). Excess weld that remains will be ground flush before
reassembly.
3. Remove the weld from point (NN) to (PP) between right heel plate (17) and hinge (12). Repeat similar weld
removal (total of four times) for left heel plate (15) and center heel plate (16). Use caution when you remove
the weld to prevent damage to hinges (12). Excess weld that remains will be ground flush before reassembly.
4. Remove left heel plate (15), center heel plate (16), and right heel plate (17) from the bucket.
Mid Plate Removal
1. Remove the weld from point (RR) to (SS) between mid plate (18) and shell (6). Use caution when you
remove the weld to prevent damage to shell (6). Excess weld that remains will be ground flush before
reassembly.
2. Remove the weld from point (RR) to (TT) and point (SS) to (UU) between mid plate (18) and hinge (12).
Use caution when you remove the weld in order to prevent damage to hinges (12). Excess weld that remains
will be ground flush before reassembly.
3. Remove the weld from point (TT) to (UU) between mid plate (18) and paddle plate (5). Damage to paddle
plate (5) is acceptable because this part will be replaced during reassembly.
4. Remove mid plate (18) from the bucket.
Paddle Plate Removal
1. Remove the weld from point (VV) to (WW) between the paddle plate (5) and hinge (12) (total four times).
Use caution when you remove the weld to prevent damage to hinges (12). Excess weld that remains will be
ground flush before reassembly.
2. Remove the weld from point (XX) to (YY) between paddle plate (5) and hinge (12) (total four times). Use
caution when you remove the weld to prevent damage to hinges (12). Excess weld that remains will be
ground flush before reassembly.
View of Section B-B from Illustration 24 (Edge Weld - Rotated View)
(a) 32 mm (1.3 inch) V-groove weld (Reference Only - Do Not Remove)
(b) 30 mm (1.2 inch) V-groove weld (Remove this weld)
3. Remove the weld from point (AB) to (AC) and point (AE) to (AD) between side plate assembly (8) and
paddle plate (5). Use caution when you remove the weld to prevent damage to side plate assembly (8).
Excess weld remaining will be ground flush before reassembly. Damage to paddle plate (5) is acceptable
because this part will be replaced during reassembly.
4. Remove the weld from point (AC) to (AD) between paddle plate (5) and edge assembly (19). See the view
of Section B-B in Illustration 25 or weld detail.
5. Remove paddle plate (5) from the bucket.
Wedge Plate Removal

Note: Use 1.3 mm or 1/16 inch diameter weld wire for ALL welds.
1. Remove the weld from point (AF) to (AG) between wedge plate (20) and shell (6) (total eight times). Use
caution when you remove the weld to prevent damage to shell (6). Excess weld that remains will be ground
flush before reassembly.
2. Remove the weld from point (AH) to (AK) between wedge plate (20) and shell (6) (total four times). Use
caution when you remove the weld to prevent damage to shell (6). Excess weld remaining will be ground
flush before reassembly.
3. Remove wedge plates (20) from the bucket (total six times).
Prepare Bucket For Component Installation
(A) Clean the existing weld from shell in area between hinges. Inspect the surface for damage from component removal. If any
cracking or gouging exists on the shell, the area MUST be welded and ground flush.
(B) Grind all weld protrusions from inside and outside surfaces of hinges.
(C) Inspect existing welds and repair if any cracking or damage exists.
(D) Clean the existing weld from the bottom surface of shell. Inspect the surface for damage caused by component removal. If any
cracking or gouging exists on the shell, the area MUST be welded and ground flush.
1. Inspect and clean all surfaces on the bottom of the bucket. Weld repair and grind smooth any damaged
surfaces. Grind smooth any existing weld protrusions.
Bucket Assembly Position
Do NOT proceed without reviewing first.
Position the bucket as shown with the top surface of the shell floor parallel to the ground and facing upwards.
Refer to Illustration 28.
Wedge Plate Installation
(a) Locate wedge plates such that bottom surface of the hinge and wedge plate are flush (six times)
(b) 86 mm (3.4 inch) (6 times)
(c) 190 ± 3 mm (7.5 ± 0.1 inch) (2 times)
1. Install six 343-2125 Plate (Wedge) (20) as shown in Illustration 29. Install edge backup strip (optional) (21)
if original backup material is damaged.
Paddle Plate Installation
(A) Weld midpoint and welding direction.
View of Section J-J from Illustration 31
(B) 3 ± 1.0 mm (0.1 ± 0.04 inch) root gap
(C) Align rear surface of paddle plate (4) to edge of bottom hinge surface. Align edge of cutout with inside surface of hinge.
(D) Contact top surface of paddle plate (4) to bottom surface of wedges.
1. Position 356-6375 Plate (Paddle) (5) and tack weld paddle plate (5) to the bucket. Confirm that the gap
between the paddle plate and the edge assembly is approximately 3 ± 1.0 mm (0.1 ± 0.04 inch) (A). Refer to
Illustrations 30, 31 and 32.
Note: Fit check right-hand one-bend plate (3) and left-hand one-bend plate (4) before beginning final weld.
Refer to the ""One-Bend Plate Installation" " section.
2. Preheat weld area to 177° C (350° F).
3. Weld a 30 mm (1.18 inch) V-groove weld with a 3 mm (0.1 inch) root gap (B) from point (AC) to (AD)
between paddle plate (5) and edge assembly (19). See Illustration 31 for view of Section J-J for welding
detail.
Note: Weld from inside to outside (reference (A) shown in Illustration 31). Cool with blankets.
4. Weld 12 mm (0.5 inch) fillet weld with 1.5 mm (0.06 inch) weld penetration from point (AB) to (AC)
between paddle plate (5) and side plate assembly (8). Repeat for both Left-Hand and Right-Hand sides.
5. Weld 12 mm (0.5 inch) fillet weld with 1.5 mm (0.06 inch) weld penetration from point (VV) to (WW)
between paddle plate (5) and hinge (12) (total four times).
6. Weld 12 mm (0.5 inch) fillet weld with 1.5 mm (0.06 inch) weld penetration from point (XX) to (YY)
between paddle plate (5) and hinge (12) (total four times).
Note: New paddle plate (5) has an improved profile and increased thickness from 30 mm (1.2 inch) to 35
mm (1.4 inch).
Mid Plate Installation
1. Position and tack weld 316-5893 Plate (Mid) (18) as shown in Illustration 33.
2. Weld a 10 mm (0.4 inch) fillet weld with a 1.5 mm (0.06 inch) penetration from point (RR) to (SS) between
mid plate (18) and shell (6) .
(a) Contact tangent to shell surface
(b) Mid plate (18) perpendicular to paddle plate (5)
(c) 20 ± 3 mm (0.8 ± 0.1 inch)
3. Weld 8 mm (0.3 inch) fillet weld with a 1.5 mm (0.06 inch) penetration from point (RR) to (TT) and point
(SS) to (UU) between mid plate (18) and hinge (12). Blend weld into existing hinge welds at the corners
(RR) and (SS) .
4. Weld 8 mm (0.3 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (TT) to (UU) between mid
plate (18) and paddle plate (5) .
Heel Plate Installation
(a) Contact edge of left heel plate (15) with rear surface of paddle plate (5)
(b) Align inside surfaces of heel plate and hinge
1. Position and tack weld 310-8998 Plate (Left Heel) (15), 310-8999 Plate (Center Heel) (16), and 310-8997
Plate (Right Heel) (17) per Illustration 35.
2. Weld 35 mm (1.4 inch) V-groove weld from point (JJ) to (KK) between right heel plate (17) and paddle plate
(5). Repeat similar weld for center heel plate (16) and left heel plate (15) .
(c) Mate bevel side surface of heel plates with bottom surface of hinge (12)
3. Weld 12 mm (0.5 inch) bevel from point (LL) to (MM) between left heel plate (15) and hinge (12). Repeat
similar weld (total of four times) for center heel plate (16) and right heel plate (17) .
4. Weld 12 mm (0.5 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (NN) to (PP) between
right heel plate (17) and hinge (12). Repeat similar weld (total of four times) for left heel plate (15) and
center heel plate (16) .
Dump Stop Plate Assembly Installation
(A) Do NOT weld across this length.
1. Locate and tack weld 316-5868 Plate As (Dump Stop) (14) per Illustrations 37 and 38 using special tool. See
the topic ""Dump Stop Locating Tool" " in ""Appendix C" ".
2. Weld 12 mm (0.5 inch) fillet weld over a 16 mm (0.6 inch) bevel weld from point (EE) to (GG) and again
from point (FF) to (HH) between dump stop plate assembly (14) and hinge (12) .
3. Weld 10 mm (0.4 inch) bevel weld from point (GG) to (HH) between paddle plate (5) and dump stop plate
assembly (14) .
4. Weld 14 mm (0.6 inch) fillet weld with 1.5 mm (0.06 inch) penetration along edges marked (EE) and (FF)
between dump stop plate assembly (14) and hinge (12) .
Dump Stop Cover Plate Installation
View of Section A-A from Illustration 40
(A) Locate: Contact rear surface of dump stop cover plate (12) over tangent to shell (5) surface.
(B) Locate: Contact bottom surface of dump stop cover plate (12) to top surface of dump stop plate assembly (13).
(c) 12 mm (0.5 inch)
1. Locate and tack weld 310-9097 Plate (Dump Stop Cover) (13) per Illustrations 39 and 40 .
2. Weld a 10 mm (0.4 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (AA) to (BB) between
dump stop cover plate (13) and shell (6) .
3. Weld an 8 mm (0.3 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (CC) to (DD) between
dump stop cover plate (13) and dump stop plate assembly (14) .
4. Weld an 8 mm (0.3 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (AA) to (CC) and from
point (BB) to (DD). Blend weld into existing weld at points (EE) and (FF) shown in Illustration 38.
5. Complete Steps 1 to 4 for both Left-hand and Right-Hand sides of the bucket.
Wing Plate and Gusset Plate Installation
(A) Locate: Flush contact between surfaces
(B) Locate: Wing plate (7) is perpendicular to paddle plate (5). Contact top edge of wing plate (7) with surface of shell (6).
1. Locate and tack weld 316-5866 Plate (Wing) (7) per Illustration 41.
2. Weld a 20 mm (0.8 inch) bevel weld from point (V) to (W) between wing plate (7) and shell (6) .
3. Weld a 12 mm (0.5 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (V) to (Y) between
wing plate (7) and hinge (12) .
4. Weld a 16 mm (0.6 inch) fillet weld with 1.5 mm (0.06 inch) penetration from point (X) to (Y) between
wing plate (7) and paddle plate (5) .
Locate: Contact all four edges of gusset plate (9) with shell (6), wing plate (7), hinge (12), and right heel plate (17)
6. Locate and tack weld 310-8981 Plate (Gusset) (9) per Illustration 42.
7. Weld a 30 mm (1.2 inch) bevel weld from point (U) to (R) to (S) to (T) between gusset plate (9) and shell
(6), hinge (12) and wing plate (7). Blend weld into the existing welds at corners (U), (R), (S) and (T) .
8. Weld a 16 mm (0.6 inch) fillet weld with 1.5 mm (0.06 inch) of penetration from point (U) to (T) between
gusset plate (9) and right heel plate (17) .
One-Bend Plate Installation
View of Section A-A from Illustration 44 ( 356-6382 Plate (One-Bend) (4) Shown)
(a) 8 mm (0.3 inch) Bevel Weld
(b) 16 mm (0.6 inch) Fillet Weld
(c) 14 mm (0.55 inch) Bevel Weld
(d) 16 mm (0.6 inch) Fillet Weld
1. Locate 356-6383 Plate (One-Bend) (3) and 356-6382 Plate (One-Bend) (4) per Illustration 44.
2. Weld a 16 mm (0.6 inch) fillet weld over a 14 mm (0.55 inch) bevel weld from point (M) to (L) between
one-bend plate (3) or one-bend plate (4) and shell (5). Due to the complex shape of the one-bend plates, the
bevel weld size will start at a minimum of 14 mm (0.55 inch) at a point (M) but increase in size as point (M)
approaches point (L). When applying the bevel weld, be sure to fill in the bevel completely between one-
bend plate (3) or one-bend plate (4) and shell (5). See Illustration 44 for a detailed view of Section A-A.
3. Weld a 16 mm (0.6 inch) fillet weld over an 8 mm (0.3 inch) bevel weld from point (N) to (P) between one-
bend plate (3) and paddle plate (4). See Illustration 44 for a detailed view of Section A-A.
4. Weld a 12 mm (0.5 inch) bevel weld from point (L) to (N). Fill entire bevel between one-bend plate (3) or
one-bend plate (4) and wing plate (6) with weld.
5. Weld a 10 mm (0.4 inch) bevel weld from point (M) to (P). Fill entire bevel between one-bend plate (3) or
one-bend plate (4) and side plate (7) with weld.
Paddle Plate Plug Welding
1. Weld a 10 mm (0.4 inch) fillet weld with 1.5 mm (0.06 inch) of penetration around the inside perimeter of
four slots marked (J). This weld is required to connect the internal gussets of dump stop plate assembly (14)
to paddle plate (5) .
2. Weld a 12 mm (0.5 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration around the inside perimeter of
6 slots marked (K). This weld is required to connect the wedge plates (20) to paddle plate (4) .
Note: Confirm 12 mm (0.5 inch) weld size in slots marked (K) .
Bottom Wear Plate Installation
(a) 50 ± 3 mm (2.0 ± 0.1 inch)
(b) 19.5 ± 3 mm (0.8 ± 0.1 inch)

(c) 24 ± 3 mm (0.9 ± 0.1 inch)
(d) 30 ± 3 mm (1.2 ± 0.1 inch)
(e) 30 ± 3 mm (1.2 ± 0.1 inch)
(f) 15 ± 3 mm (0.6 ± 0.1 inch)
1. Locate and weld 356-6377 Wear Plate (Bottom Center) (1), 356-6376 Wear Plate (Bottom Rear) (2) and the
Left-Hand/Right-Hand 356-6378 Wear Plate (Bottom Side) (11) (two times).
Note: A key design feature for bottom center wear plate (1) and bottom rear wear plate (2) is a new profile.
The new profile matches the profile of the new paddle plate (5). Weld sizes have been increased from 8 mm
(0.3 inch) to 12 mm (0.5 inch) fillet and 10 mm (0.4 inch) to 16 mm (0.6 inch) fillet respectively. Bottom
center wear plate (1) and Left-Hand/Right-Hand bottom side wear plates (11) have a perimeter weld around
outside profile.
Note: Left-Hand/Right-Hand bottom side wear plates (11) have been added on the Left-Hand/Right-Hand
sides of the bucket for additional wear protection.
Shell Wear Plate Installation
(a) 20 mm (0.8 inch)
(b) 18 ± 3 mm (0.7 ± 0.1 inch) (2 times)
(10) 356-6379 Wear Plate (Shell)
View of Section D-D from Illustration 48
1. Locate and weld the two 356-6379 Wear Plate (Shell) (10) (two times) per Illustrations 48 and 48.
Note: The weld size has been increased from 6 mm (0.2 inch) to 10 mm (0.4 inch) on rear edge of shell wear
plate (10) .
Note: Shell wear plate (10) has been added on the Left-Hand/Right-Hand sides of the bucket to provide
additional wear protection. The shell wear plates also prevent welding cracking at the rear fillet weld.
Floor Liner Wear Plate Installation/Repair
(a) 18 ± 3 mm (0.7 ± 0.1 inch) (Both Ends)
If floor liner wear plate (22) is damaged, the floor liner wear plate will need to be repaired or replaced.
Note: If the floor liner wear plate requires repair, cut the floor liner wear plate back until the damaged portion is
removed (approximately 100 mm (3.9 inch) to 125 mm (4.9 inch) is recommended). Measure the length of the
section removed and modify the replacement floor liner wear plate (22) to this length. When you cut floor liner
wear plate (22), cut at a 45 degree bevel toward the surface facing the front of the bucket, and weld to the existing
floor liner wear plate with a 12 mm (0.5 inch) bevel weld.
Appendices
Appendix A
Welding the two strap Adapters To The Base Edge
The following procedure is the recommended K series 2 strap adapter welding sequence. Refer to Special
Instruction, REHS4127, "Instructions for Welding the "K Series" Adapters" for additional information.
Side view of base edge
(A) Hard contact with base edge
(B) Hard contact with bevel of the base edge
(C) No weld
(D) Spacers
(E) Gap
1. Refer to Illustration 52. Position an adapter on the base edge at the desired location. The adapter should
make solid contact on the beveled base edge (B) and on the top surface (A). Measure the gap (E), that is
between the bottom strap and the base edge. If the gap (E) is greater than 3.0 mm (0.12 inch), place the soft
wire spacers (D) that are 2.5 mm (0.1 inch) in diameter, under the top strap. If spacers are used under the top
strap, be sure to maintain the adapter in solid contact with the beveled base edge (B) .
2. Preheat the base edge and the adapter to temperatures between 149° C and 204° C (300° F and 400° F).
When only one adapter is being replaced, preheat at least 75 mm (2.95 inch) of the base edge that is on both
sides of the adapter. Heat to temperatures between 149° C and 204° C (300° F and 400° F). Remove the heat
source. After 1 minute, recheck the temperature. If the temperature is lower than 149° C (300° F), heat
again. If more than one adapter is being replaced, tack weld each adapter halfway between the bevel and the
rear of the adapter in the weld groove of each side of the top strap.
Table 2
Dimension of the no weld area (B) at front of base edge
K90
12 ± 2 mm (0.47 ± 0.08 inch)
K100
12 ± 2 mm (0.47 ± 0.08 inch)
K110
12 ± 2 mm (0.47 ± 0.08 inch)
K130
12 ± 2 mm (0.47 ± 0.08 inch)
K150
17 ± 2 mm (0.67 ± 0.08 inch)
K170
20 ± 2 mm (0.79 ± 0.08 inch)
Top view of the adapter that has had one side welded.
(E) No stop or start on the radius of the adapter
3. Refer to Table 2 and Illustration 53. Begin the first weld pass at the J-groove that is on the top strap. Weld in
one continuous pass to the center of the back end of the adapter. If stick electrodes are used, there should be
no stops or starts at the rear radius.
Top view of an adapter with both sides welded.
(F) No stop or start on the radius of the adapter
4. Refer to Illustration 54. Move to the other side of the top strap of the adapter and apply a similar continuous
weld pass. There should be no stop or starts at the rear radii (F). Refer to Step 3.
5. Return to the first welded side and weld another pass.
6. Continue welding alternate sides of the top strap until the J-groove is filled. Do not apply fillet welds at this
time.
7. Turn over the base edge and repeat the procedure in Step 3 through Step 6 for the bottom strap.
View of staggered fillet welds
(G) Weld pass
View of staggered fillet welds
8. Continue welding the adapter with fillet welds. Alternate each pass from right side to left side of the bottom
strap, until the weld is complete. Refer to Illustrations 55 and 56. Each weld pass should start slightly behind
the previous weld pass (G) .
9. Refer to Illustration 56. Turn over the base edge and complete welding the fillet welds to the top strap.
Fillet welds should be 2 mm (0.08 inch) larger than the J-grooves.
If there would be clearance with any attached GET component next to the adapters, increase the
horizontal leg of the fillet weld by 1.25 times. For example, if the fillet weld is 16 mm (0.63 inch) high
the horizontal leg should be 20 mm (0.79 inch) high. Uneven lengths of welding legs can reduce
stresses in the toe of the weld from the flexing of the base edge.
Note: Do not allow interpass welds to cause the temperature of the adapter nose to exceed 260° C
(500° F).
Appendix B
Hinge Location and Machining Dimensions
(A) C-pin bore
(B) B-pin bore

(C) Machining dimension is before insert installation.
(D) 2X machining outer hinge bosses
(E) Insert
Hinge Bore Checking Tool (B-pin)
Materials and Notes:
200 OD X 10t X 550 mild steel tubing
12 square X 180 mild steel bar
Note: Weld bar to tube prior to machining OD of tube.
Insert the checking tool through three B-pin bores to confirm correct bore specification. Repeat for Left-Hand and
Right-Hand sides. The weight of the checking tool for the hinge bore is approximately 18.6 kg (41 lb).
Hinge Bore Checking Tool (C-pin)
Materials and Notes:
160 OD X 10t X 800 mild steel tubing

12 square X 140 mild steel bar
Note: Weld bar to tube prior to machining OD of tube.
Insert the checking tool through three C-pin bores to confirm correct bore specification. Repeat for LH and RH
sides. The weight of the checking tool for the hinge bore is approximately 14.6 kg (32 lb).
Linkage Layout Information
(A) Insert - Press fit into bucket hinge
(B) Bearing assembly (approximately 88 kg (194 lb))
(C) Checking Tube (Designed with same fit conditions as bearing assembly) - (approximately 18.6 kg (41 lb)
(D) LH/RH C-pin Link
(E) B-pin Casting
(F) Two separate pins
(G) Two separate bearings
Hinge Insert Installation
(a) 150 ton press
(b) Bearing is cooled to −49° C (−120° F) for 8 hours before pressing into machined hinge bore
(c) 282-9964 Insert (Install two pieces)
Appendix C
Dump Stop Locating Tool
(A) Dump stop locating tool
(B) Dump stop assembly
(C) Install existing 4E-5597 Pin As OR C-pin checking tool (see ""Appendix B" ").
(D) Dump stop locate tool
(E) Install B-pin checking tool (see ""Appendix B" ").
Appendix D
Shipping Dimensions and Weights
Table 3
Part
Item Qty Weight Weight (kg/lb Shipping Dimensions
Number Part Description
(kg/lb ea) total) (mm ea)
356-6377 Bottom Center Wear

1 1 179.2 kg (395 179.2 kg (395 2826 X 650 X 16
Plate
lb) lb)
356-6376 Bottom Rear Wear Plate

2 1 45.4 kg (100 45.4 kg (100 2106 X 200 X 20
lb) lb)
3 1 356-6383 One-Bend Plate (RH) 1537 X 408 X 176

18 kg (40 lb) 18 kg (40 lb)
356-6382
4 1 One-Bend Plate (LH) 18 kg (40 lb) 1537 X 408 X 176
18 kg (40 lb)
356-6375
5 1 Paddle Plate 837.1 kg 837.1 kg (1845 4570 X 1055 X 35
(1845 lb) lb)
316-5866
7 2 Wing Plate 17.3 kg (38 34.5 kg (76 lb) 922 X 167 X 20
lb)
310-8981
9 2 Gusset Plate 20.4 kg (45 40.9 kg (90 lb) 413 X 302 X 30
lb)
356-6379
10 2 Shell Wear Plate 87.0 kg (192 174.0 kg (384 2257.5 X 388 X 161
lb) lb)
356-6378 Bottom Side Wear Plate

11 2 16.1 kg (35 32.3 kg (71 lb) 900 X 367 X 10
(LH/RH)
lb)
310-9097 Dump Stop Cover Plate

13 2 2.1 kg (5 lb) 265 X 85 X 54
4.2 kg (9 lb)
316-5868
14 2 Dump Stop Plate As 37.3 kg (82 74.5 kg (164 650 X 265 X 250
lb) lb)
310-8998
15 1 Heel Plate (Left) 28.9 kg (64 28.9 kg (64 lb) 537 X 435 X 30
lb)
310-8999
16 1 Heel Plate (Center) 30.4 kg (67 30.4 kg (67 lb) 537 X 340 X 30
lb)
310-8997
17 1 Heel Plate (Right) 28.9 kg (64 28.9 kg (64 lb) 537 X 435 X 30
lb)
316-5893
18 1 Mid Plate 8.9 kg (20 lb) 8.9 kg (20 lb) 255 X 220 X 70
343-2125
20 6 Wedge Plate 10.8 kg (24 64.9 kg (143 582 X 70 X 50.3
lb) lb)
316-5897 Edge Backup Strip

21 1 5.7 kg (13 lb) 5.7 kg (13 lb) 4566 X 20 X 8
(Optional)
22 1 310-9028 Floor Liner Wear Plate 4536 X 672 X 12

282.9 kg (625 282.9 kg (625
lb) lb)
282-9964
23 2 Insert 17.0 kg (38 34.0 kg (75 lb) 255 X 255 X 150
lb)
Total 1942.5 kg
(4280 lb)
Copyright 1993 - 2019 Caterpillar Inc. Thu Dec 19 2019 10:19:18 GMT-0300 (hora de verano de Chile)
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Balde Cargador 992K

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19/12/2019 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine(SEBP4140 - 50) - Sistemas y componentes

Rework Procedure for Weld Cracks on a 294-8980 Rock Bucket Gp for

ReferenceSpecial Instruction, REHS4127, "Instructions for Welding the K Series Adapters"

This Special Instruction will cover the following:

Removal of the existing paddle plate and adjacent components

Installation of a new paddle plate and adjacent components

Installation of a new shell radius liner

Checking and remachining of the B-pin bore

Read and understand the manufacturer's instructions and your

See "American National Standard Z49.1, Safety in Welding and

American Welding Society

See "OSHA Safety and Health Standards, 29 CFR 1910", available

U.S. Department of Labor

Personal injury can result from flame cutting or welding on painted

Do not flame cut or weld on painted areas.

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Item Part Qty Part Qty

Not Replaced - Protect part from damage No Change - Reference

Plate Existing Design -

10 0 356-6379 2 Wear Plate New Design Part

Not Replaced - Protect part from damage No Change - Reference

Plate As Existing Design -

Plate Existing Design -

Plate Existing Design -

Plate Existing Design -

Not Replaced - Protect part from damage No Change - Reference

Plate Existing Design -

New Design Parts:

(1) 356-6377 Wear Plate (Bottom Center)

(2) 356-6376 Wear Plate (Bottom Rear)

(3) 356-6383 Plate (One-Bend)

(4) 356-6382 Plate (One-Bend)

(5) 356-6375 Plate (Paddle)

(10) 356-6379 Wear Plate (Shell)

(11) 356-6378 Wear Plate (Bottom Side)

General Bucket Disassembly Notes

Note: Do NOT proceed without reviewing first.

Bucket Position for Paddle Plate Rework

Prior to welding, remove the bucket from the machine.

Bottom Wear Plate and Plug Weld Removal

2. Install the hinge support bars as shown in Illustration 7.

One-Bend Plate Removal

One-Bend Plate weld (left-hand side shown)

(A) Remove 16 mm (0.6 inch) fillet weld

(B) Remove 16 X 12 mm (0.6 X 0.5 inch) filler weld

5. (Optional) Remove one-bend plate (3) from the bucket.

Hinge Gusset and Plate Removal

Dump Stop Cover Removal

4. Remove dump stop cover plate (13) from the bucket.

Dump Stop Plate Assembly Removal

3. Remove dump stop plate assembly (14) from the bucket.

Heel Plate Removal

Mid Plate Removal

4. Remove mid plate (18) from the bucket.

Paddle Plate Removal

(a) 32 mm (1.3 inch) V-groove weld (Reference Only - Do Not Remove)

(b) 30 mm (1.2 inch) V-groove weld (Remove this weld)

5. Remove paddle plate (5) from the bucket.

Wedge Plate Removal

Prepare Bucket For Component Installation

Bucket Assembly Position

Do NOT proceed without reviewing first.

Wedge Plate Installation