Rework Procedure for Dump Stops{6001} Caterpillar

Wheel Loader:

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

Introduction

This Special Instruction describes the rework procedure for installing improved dump stops on 988G Wheel Loader and some 988H Wheel Loader buckets. The new stops are made of solid rubber with a separate steel top plate. The improved design will help prevent the stops from either separating at the layers or falling off the bucket due to broken mounting bolts.

The new design for the stop replaces the 184-9866 Stop and the 8T-4139 Bolts . The new stops are used on new 988H Wheel Loader buckets. Some aftermarket buckets and some specialized buckets may not accommodate the new stops.

Machine Preparation

1. Move the machine to a surface that is smooth, hard, and level. Move the machine to an area that is away from operating machines and away from personnel.

2. Install blocks on the front and the rear of the front tires.

Preparing the Area for Welding

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

Clean the area in order to be welded. Clean the area of the following substances:

• Oil

• Grease

• Paint

• Dirt

If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding procedure.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from the sparks. Protect machined surfaces from the weld splatter.

Rework Procedure

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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.

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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

Note: The outer hinge plate has been removed from the following graphics for a better view of the dump stop.

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Illustration 1	g01144788
988G bucket with current dump stop

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Illustration 2	g01144805
Right side dump stop The outer hinge plate is not shown.

1. Remove the current dump stop from the mounting pad.

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Illustration 3	g01144819
All dimensions in millimeters (1) 225-9602 Plate . (2) Mounting pad.

2. Mount 225-9602 Plate (1) 17.25 mm (0.679 inch) below the center of the bottom holes of existing mounting pad (2). Create a 6 mm (0.2 inch) bevel weld between the bottom of plate (1) and mounting pad (2). Create a 7 mm (0.3 inch) fillet weld along the bottom edges between plate (1) and the hinge plates.

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Illustration 4	g01144843
All dimensions in millimeters (3) Hinge plate. (4) 225-9482 Bar .

3. Mount 225-9482 Bar (4) 52 mm (2.0 inch) from the existing mounting pad. The bar will be flush with top of plate (1). Create a 6 mm (0.2 inch) fillet weld between hinge plate (3) and the top of bar (4) that runs the full length of the bar. Repeat this procedure for the bar on the other side of plate (1) .

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Illustration 5	g01144851

4. Insert 228-4727 rubber pad (5) and 225-9584 steel plate (6). The vertical bevels on rubber pad (5) face the existing mounting pad. The steel plate should be positioned toward the outside of the bucket.

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Illustration 6	g01144852

5. Install 257-3651 top plate (7). Create a 12 mm (0.5 inch) bevel weld along the three sides of the top plate. Then, create a 14 mm (0.55 inch) fillet weld on the short sides between the top plate and the hinge plates.

6. Repeat the process for the dump stop on the left side.

7. The tilt sensor must be recalibrated after the new dump stops are installed in order to ensure that the linkage operates with the designed amount of contact with the dump stops. When you are performing the calibration, you must set the travel limit (dump) by fully dumping the bucket after the lift linkage is completely raised.

   Reference: For reference, see Testing and Adjusting, RENR2171, "Position Sensor for the Tilt Linkage (Electronic Technician) - Calibrate".

Reference Dimensions

Illustration 7	g01144932
Front View All dimensions in millimeters (1) 225-9602 Plate . (2) Mounting pad. (3) Hinge plate. (4) 225-9482 Bar . (7) 257-3651 Plate .

Illustration 8	g01144934
Side View Dimensions in millimeters (1) 225-9602 Plate . (2) Mounting pad. (4) 225-9482 Bar . (5) 228-4727 Rubber pad . (6) 225-9584 Steel plate . (7) 257-3651 Plate .