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Service Training SERV1770Meeting Guide 770 May 2003

TECHNICAL PRESENTATION

992G WHEEL LOADER

BEST MAINTENANCE PRACTICES

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992G WHEEL LOADERBEST MAINTENANCE PRACTICES

MEETING GUIDE 770 VISUALS AND SCRIPT

AUDIENCE

Dealer and customer personnel who are responsible for the daily maintenance and service of the 992G

Wheel Loader.

CONTENT

This presentation provides basic information for the 992G Wheel Loader front linkage. It is intended to

be used in conjunction with existing training material and service manuals.

OBJECTIVES

After learning the information in this meeting guide, personnel will be able to:

1. perform a Daily Walk-Around Inspection with emphasis on the front linkage;

2. identify problems before the problems become failures; and

3. inspect and maintain the pin flag retention systems.

REFERENCES

992G (7HR, ADZ) Wheel Loader Service Manual SENR1344992G (7HR, ADZ) Wheel Loader Operation and Maintenance Manual SEBU7009

992G (7HR, ADZ) Wheel Loader Operation and Maintenance Manual SEBP2989

992G (7HR, ADZ) Wheel Loader Boom Stop Maintenance Special Instruction REHS0250

992G (7HR, ADZ) Wheel Loader Autolube Field Installation Special Instruction REHS1349

992G (7HR, ADZ) Wheel Loader Autolube System Instruction REHS1395

992G (7HR, ADZ) Wheel Loader Installation and Replacement Procedure for

Greased Link Pin Joints Special Instruction REHS1501

Dimensions for Articulated Hitches Special Instruction SEHS8642

992G (7HR, ADZ) Wheel Loader Daily Walk-Around Inspection

Technical Information Bulletin TIBU3641

Estimated Time: 4 Hours

Visuals: 21 Visuals

Student Handouts: 4

Form: SERV1770

Date: 5/03

2003 Caterpillar Inc.

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TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................4

REWORK PROGRAMS .......................................................................................................5

BEST MAINTENANCE PRACTICES SERVICE LITERATURE ......................................6

DAILY WALK AROUND INSPECTION ............................................................................7

PIN FLAG RETENTION MAINTENANCE.......................................................................17

MEASURE JOINT STACK UP ...........................................................................................19

COMPONENT REPLACEMENT ......................................................................................20

BEARING REMOVAL ........................................................................................................21

PIN JOINT ASSEMBLY......................................................................................................22

BREAK IN PROCEDURE...................................................................................................23

PRE-DELIVERY PROCEDURE .........................................................................................24

CONCLUSION.....................................................................................................................25

VISUAL LIST .....................................................................................................................26

DAILY WALK AROUND INSPECTION CHECKLIST ...................................................27

STUDENT HANDOUTS .....................................................................................................30

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INTRODUCTION

This presentation identifies the best maintenance and service practices for

the 992G Wheel Loader structures.

The presentation will cover a service literature list, a daily machineinspection, and a pin flag retention maintenance. Component

replacement, installation procedure, and break-in procedure for pins and

bearings will also be covered.

Several handouts containing key information regarding 992G Wheel

Loader best maintenance practices are located at the end of this Service

Training Meeting Guide. The handouts are intended for copying and use

in class. The handouts can also be copied, laminated, and used by service

personnel on a daily basis.

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2003 Caterpillar Inc.

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992G WHEEL LOADERLINKAGE REWORK PROGRAMS

PI30110/PI30368 Linkage Pin Conversion to Daily Grease

PS40808 Discounted Purchase Price for Autolube

REWORK PROGRAMS

The rework programs listed above should be completed on a 992G Wheel

Loader in order to realize the expected life of the linkage. All pins should

be converted to daily grease and Autolube should be installed on the

machine.

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992G WHEEL LOADER

BEST MAINTENANCE PRACTICESSERVICE LITERATURE LIST

REHS0250 Boom Stop MaintenanceREHS1349 Autolube Field Installation

REHS1395 Autolube System Instruction

- Available in Paper Only by Ordering REHS1396

REHS1501 Installation and Replacement of Grease Pins

SEHS8642 Dimensions for Articulated Hitches

TIBU3641 Daily Walk Around Inspection

BEST MAINTENANCE PRACTICES SERVICE LITERATURE

This graphic lists the service literature containing information regarding

maintenance of the 992G Wheel Loader linkage. Personnel responsible

for maintaining and servicing the 992G Wheel Loader should be supplied

with the literature listed above.

NOTE: The instructor should provide the students with the above

literature and go over the literature in class.

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DAILY WALK-AROUND INSPECTION

A walk-around inspection should be performed daily on the 992G Wheel

Loader. All pin joints should be checked for loose or damaged

components, proper lubrication, and operation. It is important to identify

a potential problem before the problem becomes a failure.

NOTE: Refer to SEBU7009, 992G Wheel Loader Operation and

Maintenance Manual, for additional information regarding the daily

walk-around inspection for the 992G Wheel Loader.

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The condition of the lubrication delivery system should be checked daily.

The lines, the hoses, and the injectors should all be inspected. When

damaged components are found, those components should be repaired or

replaced immediately.

Starting at the articulation joint on the left side of the machine, the

inspector should check the condition of the hoses (1) and the injectors (2).

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2

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Standing in the same location and looking up, the inspector can check the

lubrication lines (1) and (2) and the hoses for the A pin and G pin. The

inspector should also check the end plates (3) and (4) and the bolts (5).

This is a visual inspection, checking for loose or damaged parts.

The inspector should also check the left end of the Y pin (not pictured)

from this location.

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Moving forward around the front left tire, the inspector should check the

lines and the hoses (1), (2), and (3) and the injectors (4). The end plate

(5) and bolt (6) for the K pin should be checked also.

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The E and F pin areas can be checked from the same location. The

inspector should check the flag, retaining plate, retaining bolts, and the

lubrication lines at the E pin (1). The lubrication line (2) should be in

good condition with no leaks. At the F pin (3), check the flag, the

retaining plates, the retaining bolts, and verify there is grease exiting the

relief valve.

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Check the hoses (1), the lines (2), and the injectors (3) on the bottom of

the bucket link (4).

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From the right side of the machine, check the hoses (1) and the lines (2)

on the bottom of the bucket link (3). Any leaks or damaged components

should be repaired immediately.

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On the right side of the K pin, check the flag (1), the retaining plate (2),

and the fasteners (3). Grease should be exiting relief valve (4).

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2

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