Installation of the Blank Hooks{6001, 6129} Caterpillar

Blank Hook:

QUICK COUPLER (S/N: AAP1-UP; ABN1-UP; ACD1-UP; AKL1-UP; ADS1-UP; AEW1-UP; ALG1-UP; AFJ1-UP)

Introduction

The Special Instruction, REHS1044 describes the necessary procedures for you to install the Blank Hook. If you need more information in order to install the hooks, consult your Caterpillar dealer.

Do not perform any procedure and do not order any parts until you understand the information that is contained in this document.

Required Parts

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Illustration 1	g01127451

Dimensions

Illustration 2	g01127456

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 ""Preparing the Metal for Welding" ". 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.

Removal of Existing Hooks

In order to remove the existing hooks, use the following steps:

1. Set the work tool on a smooth surface. Adjust the work tool until the work tool is level.

2. Remove the work tool from the host machine.

3. Gouge out welds from the work tool. After you remove the hooks, weld the gouges. Grind the surface smooth.

Creating a Profile

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Illustration 3	g01127467
(1) Cardboard template (2) Ruler or straight edge (3) Reference line (4) Outline of profile

1. Place a large piece of cardboard (1) against the side of the bucket. The cardboard will be used as a template for the new hooks.

2. Copy the profile (4) of the box section of the bucket onto the cardboard.

   Note: The profile of the box section is not the same profile as the profile of the side of the bucket. You must make sure that you copy the profile of the box section of the bucket.

3. Place a large ruler or straightedge (2) on the cutting edge of the bucket (5). Place the other end of the ruler or straightedge on the box section (6) of the bucket.

4. Draw a reference line (3) on the template.

5. Hold the cardboard against the side of the bucket. The profile of the box section must be aligned with the profile on the template. The ruler or the straightedge (2) must touch the template.

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Illustration 4	g01127476

6. Cut the profile (4) of the box section of the bucket from the template.

7. After you have cut out the profile, place the profile on the box section of the bucket. The profile of the template must match the profile of the box section. If necessary, trim the cardboard template.

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Illustration 5	g01127477
(1) Cardboard template (2) Ruler or straight edge (3) Reference line (4) Outline of profile (5) Reference line on the hook (6) Blank hook

8. Align the ruler or the straightedge (2) with the reference line (3) that is on the hook (6) .

9. Align the template (1) on the blank hook (6). Align the reference mark (3) with the edge of the ruler. You must make sure that the outline of the profile is below the reference marks (5) on the hook.

10. Use a center punch to mark the outline of the profile of the box section.

11. Remove the template (1) from the blank hook (6) .

12. Use a cutting torch to cut out the profile.

13. Allow the hook to cool to room temperature. Grind away any debris that remained from cutting the profile.

14. Place the hook on the bucket. If necessary, grind away any material that interferes with the fit of the bucket.

15. Place the first hook onto the second hook. Copy the profile from the first hook onto the second hook. Use a center punch to mark the outline of the profile.

16. Use a cutting torch to cut out the profile.

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Illustration 6	g01127479

17. Grind a bevel on the edges of the profile (7). Refer to Table 3 for the depth of the bevel.
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    Table 3

    Depth of the Bevel
    Part Number	Angle of the Bevel	Dimension (C)
    183-6979, 183-6985	0°	0 mm (0 inch)
    183-6980, 183-6986	40°	12 mm (0.5 inch)
    183-6981, 183-6987	40°	15 mm (0.6 inch)
    183-6982, 183-6988	40°	20 mm (0.8 inch)
    183-6883, 183-6989	40°	25 mm (1.0 inch)

18. Obtain two strips of steel that are strong enough to hold the hooks in position.

19. Fit the new hooks into the proper quick coupler. Measure the new hooks. Ensure that the hooks are properly aligned in the coupler. The new hooks must be perpendicular to the bottom of the coupler.

20. After you have aligned the hooks, tack weld the strips of steel to the hooks. The strips must be positioned in order to keep the hooks aligned.

21. Carefully move the hooks to the work tool.

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Illustration 7	g01127484

22. Position the hooks on the work tool.

23. Place the straight edge (2) from the cutting edge to the top edge of the bucket. The reference line (3) must be parallel to the straight edge (2). If necessary, grind the material from the bottom edge of the hooks.

24. Tack weld the hooks into position.

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Illustration 8	g01127488

25. Place rod (8) into the hook of the new hooks. Clamp the rod into position.

26. Visually check the alignment of the rod with the lower edge of the work tool. The rod must be parallel with the cutting edge of the bucket. Check the alignment in at least two places.

27. Measure distance (D) from the cutting edge to the rod. Measure distance (D) at both ends of the rod. The dimension at distance (D) between the cutting edge and the rod must be the same dimension at both locations. If the dimension of distance (D) between the cutting edge and the rod is not the same dimension at both locations, move one hook.

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Illustration 9	g01127490

Note: Before you weld the hooks in place, preheat the entire hook to 200° C (392° F) using a propane torch or oven. Allow to cool slowly. Use heat blankets to slow the cooling if necessary.

28. Weld the hooks into position. Refer to Table 4 for the size of the weld.
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    Table 4

    Size of the Weld
    Part Number of the Hook	Size of the Weld
    183-6979, 183-6985	6 mm (0.2 inch)
    183-6980, 183-6986	8 mm (0.3 inch)
    183-6981, 183-6987	10 mm (0.4 inch)
    183-6982, 183-6988	12 mm (0.5 inch)
    183-6883, 183-6989	15 mm (0.6 inch)

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Illustration 10	g01127491

29. Cut the two lower lips (9) from the excess material from the hooks.

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Illustration 11	g01127493

30. Machine the bevels on the hook and on the lip. Refer to Table 5 for the proper angle.
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    Table 5

    Angle of the Bevel
    Part Number of the Hook	Angle (E)
    183-6979, 183-6985	60°
    183-6980, 183-6986	60°
    183-6981, 183-6987	60°
    183-6982, 183-6988	60°
    183-6883, 183-6989	60°

31. Weld the lower lip into position.

32. Allow the welds to completely cool.

33. Remove the strips of steel from the hooks.

34. Remove all of the debris from the welding. Paint the area that was welded with primer.

35. Allow the primer to completely dry. Finish the areas with a final coat of paint.