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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.

    999922GGWWHHEEEELLLLOOAADDEERR

    BBEESSTTMMAAIINNTTEENNAANNCCEEPPRRAACCTTIICCEESS

    2003 Caterpillar Inc.

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    2

    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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    2

    3

    4

    5

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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.

    1

    3

    2

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    5

    6

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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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