2007/04/23 Caterpillar

Wheel Loader:

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

988H (S/N: BXY1-UP)

Work Tool:

BUCKET (S/N: 7NW1-UP)

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

The spillguard on some 988H buckets may become damaged in certain applications. Use the following repair instructions if the spillguard becomes bent, broken, or cracked. This modification will increase the strength and durability of the bucket.

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Illustration 1	g01368382
Typical Example (1) Long Gusset (2) Short Gusset

Note: Before additional gussets can be added, the existing gussets must be straightened. This can be accomplished by heating and bending the plates back into shape.

1. Repair all cracks by gouging out and rewelding. Use "E7018" welding rod or the equivalent. Refer to Special Instruction, REHS1841, "General Welding Procedures".

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Illustration 2	g01368365
Typical example (1) Long Gusset (2) Short Gusset

Note: Additional gussets will be placed between the existing gussets in order to add stiffness to the current bucket design. Refer to table 1 for the part numbers of the gussets.

2. Install the new gussets in the middle of the slots that are located on the bucket. Refer to illustration 2.

   1. Prepare the mounting locations by using a sanding disc that is made of aluminum oxide to remove the paint from the areas. After you have removed the paint from the mounting surfaces, clean these areas thoroughly in order to remove any debris.

   2. Tack weld the gusset to the bucket.

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Illustration 3	g01368458
(W1) 1.5 mm (0.06 inch) Penetration (W2) 8 mm (0.32 inch) Fillet weld on both sides (L1) Continuous weld from location (A) to location (B) (L2) Continuous weld from location (C) to location (D) (L3) Continuous weld from location (E) to location (F) (L4) Continuous weld from location (G) to location (H) (N1) Stop the weld 10 mm (0.4 inch) from the end of the gusset. (J) 10 mm (0.4 inch)

3. Weld the new gussets into position by using an 8 mm (0.32 inch) fillet weld on both sides of the gusset. Use "E7018" welding rod or the equivalent. Stop the weld 10 mm (0.4 inch) before the end of the gusset. Refer to illustration 3.

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Illustration 4	g01368537
Typical example (W3) 1.5 mm (0.06 inch) Penetration (W4) 6 mm (0.24 inch) Fillet weld

Note: This step is optional. This modification requires covering the slots. By covering the slots, additional strength will be achieved.

4. Fabricate a 12 mm (0.5 inch) thick plate. Place the plate over the existing slots in the bucket. Use a 6 mm (0.24 inch) fillet weld around the plate.

5. Clean the welds and inspect the welds.

6. Paint the welds and the weld areas in order to prevent corrosion.