Installation of the 520-6470 Blank Hook As. on Certain Wheel Loaders {6102} Caterpillar


Installation of the 520-6470 Blank Hook As. on Certain Wheel Loaders {6102}

Usage:

7NW
Wheel Loader
980K (S/N: W7K1-UP; GTZ1-UP)
980M (S/N: 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.

Required Parts

Table 1
520-6470 Blank Hook As. (- 00) 
Part No.  Part Name  Qty 
520-6470  Blank Hook As. 

Welding Requirements

------ WARNING! ------

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

------ WARNING! ------

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. Place a 600 mm (24 inch) or longer level on the work tool. Adjust the work tool until the work tool is level.

  2. Remove the work tool from the host machine.

    Note: Bucket shown in this media is the 361-5001 Rock Bucket Gp.



    Illustration 1g06130876
    Parts to be removed are colored purple.


    Illustration 2g06130880
    View of bucket with existing hooks removed.

  3. Gouge out welds (2) or trim existing hooks (1) from the work tool. After you remove the hooks, weld the gouges. Grind the surface smooth.

    Note: When the 520-6470 Blank Hook As. is installed on a bucket, do not remove the existing box sections (3) at the base of the bucket.

Creating a Profile

Note: A profile can be created to convert a flat hook into a blank hook. The 520-6470 Blank Hook As. is supplied with the 521-0812 Plates that are used to create a profile. Consult your Caterpillar dealer about these plates.

Note: The back edge of the plates must be perpendicular to the ground. If the edge of the plates are not perpendicular to the ground, you must weld the edges until the edges are perpendicular, or you must replace the plates. The back edge of the plates must be as close to the work tool as possible.



Illustration 3g06130890
Use this Illustration as a typical example.
(A) 1003 mm (39.4 inch)

Procedure to Mark the Plates

Note: The back edge of the plates (4) must be perpendicular to the ground. If the back edge of the plates are not perpendicular to the ground, you must weld the edges until the edges are perpendicular, or you must replace the plates. The back edge of the plates (4) must be as close to the work tool as possible.



    Illustration 4g06130890

  1. Use a sheet of cardboard at the center of the bucket to create a profile. Locate the top of the cardboard 1003 mm (39.4 inch) (A) from the surface.

  2. Cut the cardboard to the existing profile of the bucket.

  3. Align the edge of cardboard with the edge of the 521-0812 Plates. Keep the profile of the bucket or the work tool as close to the back edge of the plates as possible.

  4. Cut the profile of the bucket or another work tool into the plate. Repeat this step for each of the plates.

Weights

------ WARNING! ------

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.


Table 2
Part Number and Part Name  Weight 
520-6470 Blank Hook As.  830.6 kg (1831.1 lb) 

Use a suitable lifting device to lift the 520-6470 Blank Hook As. into the proper location to weld to the work tool.

Installation of the 520-6470 Blank Hook As.

  1. Center the 520-6470 Blank Hook As. on the back of the work tool. Set a 600 mm (24 inch) or longer level on the top of the hooks to level the hook assembly on the work tool.

  2. Position the top of the 520-6470 Blank Hook As. 1003 mm (39.4 inch) from either the bottom of the work tool or from the ground.

  3. Tack weld the 520-6470 Blank Hook As. to the work tool. The weld must be sufficient enough to allow the work tool to be moved. This allows the work tool to be lifted. The work tool can also be rotated.

  4. Couple the work tool to the quick coupler to check the accuracy of the location of the flat hook. Engage the locking pins. Move the bucket to the rack back position. Move the bucket to the dump position. Check that the coupler does not interfere with bucket operation or machine operation.

  5. Set the work tool on the ground. Disengage the quick coupler. As needed, make adjustments to the location of the 520-6470 Blank Hook As..


    Illustration 5g06130896
    Typical weld example.

  6. Weld the 520-6470 Blank Hook As. to the work tool. Use 1U-5234 Welding Rod. The welds should be 8 mm (0.31 inch) wide or larger.

  7. After the welds cool, couple the work tool to the quick coupler. Engage the locking pins. Move the bucket to the rack back position. Move the bucket to the dump position. Check that the coupler does not interfere with bucket operation or machine operation.

    Note: Step 7 should only be done when the 520-6470 Blank Hook As. is installed on a bucket.

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