ENGINE AR-CORE 4516127 - Caterpillar

Table 1
Dimensions of the Quick Coupler
Quick Coupler Group Model Maximum Allowable Gap
240-4044 301 20 mm (0.78 inch)
240-4061 302
BH27
BH30
BH30W 23 mm (0.90 inch)
240-4078 303
BH150
BH160 26 mm (1.02 inch)
240-4095 304
304.5
304CR
305CR 26 mm (1.02 inch)
276-5720 304C CR and 305C CR 30 mm (1.18 inch)
324-0161 307D and 308D 33 mm (1.30 inch) Note: Attach a known good bucket or a Work Tool to inspect the Coupler. See table 2 for dimensions of the bucket. Load the actuating lever against the Safety Pin to inspect the Coupler. Dimensions for the Gap exceeding the dimensions that are between the Connection Pin for the Work Tool and the Hook are located in table 3. Recondition the Coupler to attain a tighter fitup of the Work Tool.
Table 2
Bucket Pin Spread.
Model Dimension
301 126.4 1.25 mm (4.98 0.05 inch)
302
BH27
BH30
BH30W 165 1.25 mm (6.50 0.05 inch)
303
BH150
BH160 200 0.63 mm (7.87 0.02 inch)
304CR
304C CR
305CR
305C CR 260.5 0.63 mm (10.26 0.02 inch)
307D and 308D 305.9 0.63 mm (12.04 0.02 inch)
Table 3
Clearance between Connection Pin for the Work Tool and Hook
Clearance Quick Coupler Group
4 mm (0.16 inch) 240-4044
240-4061
240-4095
3 mm (0.12 inch) 240-4078
276-5720
324-0161 Rework Procedure for Quick Coupler
Illustration 8 g01643097
(A) Hook
(B) Worn Area
Measure the amount of Gap (F) that is located between Hook (A) and Safety Pin (G). Use a known good bucket for reference. See Table 3 for the maximum dimension for Gap (F) after reworking the Coupler. After the rework process if there is no clearance at Gap (F), some Work Tools may no longer fit into the Coupler. See illustration 11.
Disassemble the Coupler (E) and remove Hook (A).
Once Hook (A) is removed, inspect worn area (B) for rework.
Prepare area (B) for welding. Proper preparation will ensure an improved weld.
Illustration 9 g01643236
(C) Weld
Apply weld (C) to the prepared area to build up the material. Welding will minimize Gap (F) once Hook (A) is installed.Note: It is recommended that you rebuild the Coupler no more than two times. This is due to multiple components that contribute to the overall wear of the Coupler.
Illustration 10 g01643355
(D) Original Profile
Grind the weld so that the weld is near the original profile (D).
Illustration 11 g01643413
(A) Hook
(E) Coupler
(F) Gap
(G) Safety Pin
Assemble Hook (A) with Coupler (E). Also attach a known good bucket or a Work Tool to inspect Coupler (E). Load the actuating lever against Safety Pin (G) to inspect Coupler (E). Gaps that exceed the dimension between the face of the Connection Pin for the Work Tool and Hook (A) can be found in table 3.Note: If the Pin (Hook Pivot) bore on the Coupler becomes over sized by a dimension of 3 mm (0.12 inch), it is recommended that the coupler be welded and line bored or replaced with a new coupler group.Note: Ensure that all Work Tools fit properly on the reworked coupler before placing the machine back into service.