1.-Prácticas de Mantenimeinto

8/10/2019 1.-Prácticas de Mantenimeinto

http://slidepdf.com/reader/full/1-practicas-de-mantenimeinto 1/34

Service Training SERV1770

Meeting Guide 770 May 2003

TECHNICAL PRESENTATION

992G WHEEL LOADER

BEST MAINTENANCE PRACTICES



992G WHEEL LOADER BEST 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.



STMG 770 - 3 -

5/03

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



STMG 770 - 4 -

5/03

1

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.

999922GG WWHHEEEELL LLOOAADDEERR

BBEESSTT MMAAIINNTTEENNAANNCCEE PPRRAACCTTIICCEESS

© 2003 Caterpillar Inc.



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.

STMG 770 - 5 -

5/03



STMG 770 - 6 -

5/03

3

992G WHEEL LOADER

BEST MAINTENANCE PRACTICESSERVICE LITERATURE LIST

• REHS0250 Boom Stop Maintenance• REHS1349 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.



STMG 770 - 7 -

5/03

4

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.



STMG 770 - 8 -

5/03

5

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).

1

2



STMG 770 - 9 -

5/03

6

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.

1

2

3

4

5



STMG 770 - 10 -

5/03

7

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

4

5

6



STMG 770 - 11 -

5/03

8

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.

1

3

2



STMG 770 - 12 -

5/03

9

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

the bucket link (4).

12

34



STMG 770 - 13 -

5/03

10

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.

1

2

3



STMG 770 - 14 -

5/03

11

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).

1

2

4

3



STMG 770 - 15 -

5/03

12

Move to the rear of the right front tire and visually inspect the right side

of the G pin (1) and the A pin (2). Again, check the flags, the retaining

plates, and the fasteners looking for damage or looseness. Also check for

grease exiting the relief valves.

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

from this location.

NOTE: Refer to TIBU3641 for additional information regarding the

daily walk-around inspection.

NOTE: At this time, the students should perform a daily

walk-around inspection on a 992G Wheel Loader.

1

2





STMG 770 - 17 -

5/03

14

PIN FLAG RETENTION MAINTENANCE

The 992G Wheel Loader linkage design transfers the bucket side loads

through the pin flags (1) at the A and B pins. The surfaces between the

flag, the retention plate (2), and the retention block on the bucket are not

lubricated and do wear over time allowing increased motion. The

increased motion will increase the wear rate and if allowed to progress

can cause interference between the frame and the boom or the boom and

the bucket. The following should be used as a guideline for flag and

retainer maintenance.

1. The nominal design clearance between the pin flag (1) and the

retention plate (2) is 2.0 mm axially (pin in-and-out) and 3.0 mm

radially (pin turning).

2. The minimum clearance between the pin flag (1) and the retention

plate (2) should be 0.5 mm axially and radially.

3. When the clearance grows to greater than 6 mm axially or radially the

joint should be rebuilt so the clearance falls between the minimum

and nominal range.

1

2



STMG 770 - 18 -

5/03

4. The rebuild can be a combination of replacing the retention plate,

building up the worn area of the retainer block (located behind the

retention plate) with weld, and tack welding shim stock to the

retention plate.

5. Whenever a new pin is installed, the clearance between the pin flag

and retention plate should be checked to be sure they fall within the

guidelines listed above.



STMG 770 - 19 -

5/03

15

MEASURE BEARING STACK UP

Before disassembly and after assembly, it is important to measure bearing

stack up. Bearing stack up is dimension “S” in the pin joint cutaway on

the left. If bearing stack up is not within the specification listed in the

table above, corrective action must be taken.

Pin joint life will be significantly reduced if bearing stack up is out of

specification.



STMG 770 - 20 -

5/03

16

992G WHEEL LOADERCOMPONENT REPLACEMENT GUIDELINES

• New Pin = New Bearing

• Replace Both the Pin and Bearing When Galling or

Metal Pickup is Present on Either Part

• Replace Both the Pin and Bearing When the

Pin Diameter Has Been Reduced by More Than 3 mm

COMPONENT REPLACEMENT

The graphic above lists three guidelines for component replacement on

the 992G front linkage.

Always replace the bearing when a new pin is used. The bearing is coated

with a black crystalline material that adds to the break-in process between

the pin and bearing.

The pin and the bearing should both be replaced when there is galling or

metal pickup on either component.

The pin and the bearing should both be replaced when wear has reduced

the diameter of the pin by 3 mm.

NOTE: Refer to REHS1501 for more detailed information regarding

component replacement.



STMG 770 - 21 -

5/03

17

* Any Damage to the Bore or Spacer

During Bearing Removal Must be Repaired before Beginning Installation

Remove Approximately 2/3of the Bearing Thickness

in Four Locations

992G WHEEL LOADER

BEARING REMOVAL GUIDELINES

BEARING REMOVAL

The bearings on the 992G Wheel Loader front linkage should be removed

using the method shown above.

Cut the bearing approximately 2/3 through the thickness of the bearing in

four equally spaced locations around the internal circumference. Take

care not to damage the spacer or the bore while cutting the bearing. When

the bearing cools it should shrink enough to allow easy removal.

If the spacer is damaged it must be replaced or repaired. Grease can leak

out of the pin joint with a damaged spacer, causing an early hour failure.

A damaged bore must be repaired with acceptable weld practices before

installing the new bearings.



STMG 770 - 22 -

5/03

18

992G WHEEL LOADER PIN JOINT GUIDELINES

• Measure the Bearing Stack Up before Removal

• Lower the Temperature of Bearings to -73 C (-100 F) before Assembly• Apply RTV Silicone Sealant to Each End of the Bearing Spacer

before Assembly

• Install the Bearing Offset on the Flag Side of the Pin Joint

• Install the Installation Press and Apply Pressure until the

Bearings Have Warmed to Prevent Walking

• Measure the Bearing Stack Up

• Clean the Bore and Apply 1E-2078 Antiseize to the Bore

before the Installation of the Collar

• Coat the Pin, Bearings, and the Inside of the Collars with

SAE 80W90 Oil

• Do Not Use Excessive Force when Installing the Pin

• Fill the Pin Joint with Grease

• Perform the Break-In Procedure

PIN JOINT ASSEMBLY

The above graphic lists guidelines for servicing pin joints on the 992G

Wheel Loader.

NOTE: Refer to REHS1501 for additional information regarding the

servicing of pin joints.



STMG 770 - 23 -

5/03

19

BREAK IN PROCEDURE

Following any pin or bearing replacement, the pin joints on the 992G

Wheel Loader needs to be broken in. The break-in procedure insures the

pin joints are working properly and receive ample lubrication as the pin

and bearings wear in.


break in procedure for the pin joints.


daily walk-around inspection for the pin joints.



STMG 770 - 24 -

5/03

20

PRE-DELIVERY PROCEDURE

A pre-delivery procedure should be completed on a new 992G Wheel

Loader. Similar to the break-in procedure, the pre-delivery procedure

includes installing the bucket and checking the dump stops.

NOTE: Refer to SENR1344 for additional information regarding the

installation of the B and C pins.

NOTE: Refer to REHS0250 for additional information regarding

checking the alignment of the dump stops.


break in procedure for the pin joints.


daily walk-around inspection for the pin joints.



STMG 770 - 25 -

5/03

21

CONCLUSION

The 992G Wheel Loader linkage will provide the expected service life

when it is serviced and maintained correctly.





STMG 770 - 27 -

5/03

992G WHEEL LOADER BEST MAINTENANCE PRACTICES

Daily Walk-Around Inspection Checklist

Articulation Hitch (left side of the machine)Articulation joint upper and lower hitch pins

_____ Grease exiting the face seals and/or the relief fittings

Lines, hoses, and injectors

_____ No leaks

_____ No damaged or missing parts

Left end of the A, G, and Y pins _____ Retaining plate in good condition

_____ Retaining bolt tight

_____ No grease exiting the joint

_____ Lubrication lines in good condition

Forward of the Left Front Tire

Lines, hoses, and injectors near lift cylinder

_____ No leaks


Left end of the K pin

_____ Retaining plate in good condition


_____ No grease exiting the joint


Left End of the E Pin

_____ Retaining plate and flag in good condition

_____ Retaining bolts tight

_____ Grease exiting the joint




STMG 770 - 28 -

5/03

Left End of the F Pin



_____ Grease exiting the relief fitting

Left End of the B Pin



_____ Grease exiting the relief fitting only


Left End of the C Pin



_____ Grease exiting the pin joint


Lines, hoses, and injectors under the bucket tilt link

_____ No leaks


Forward of the Right Front Tire

Right end of the B pin



_____ Grease exiting the relief fitting only


Right end of the C pin



_____ Grease exiting the pin joint






STMG 770 - 30 - Student Handout 1

5/03

A

G

Y

B C

E

F

K

G r e a s e

E x

i t i n g

B e

t w e e n

J o i n

t F a c e s ,

R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

P l a t e i n G o o

d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e s

i n G o o

d C o n

d i t i o n

G r e a s e

E x

i t i n g

B e

t w e e n

J o i n

t F a c e s ,

R e

t a i n i n g

B o

l t s T i g h t ,

R e

t a i n i n g

F l a g a n

d P l a t e i n G o o

d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e s

i n G o o

d C o n

d i t i o n

N o

G r e

a s e

E x

i t i n g

J o

i n t ,

R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

P l a t e i n G o o

d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e

i n G o o

d C o n

d i t i o n

N o

G r e a s e

E x

i t i n g J

o i n t ,

R e

t a i n i n g

B o

l t T i g h t

,

R e

t a i n i n g

P l a t e i n G

o o

d

C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e

i n G

o o

d

C o n

d i t i o n

N o

G r e a s e

E x

i t i n g

J o

i n t ,

R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

P l a t e i n G o

o d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e

i n G o

o d C o n

d i t i o n

N o

G r e a s e

E x

i t i n g

J o

i n t ,

R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

P l a t e i n G o o

d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e

i n G o o

d C o

n d i t i o n

G r e a s e

E x

i t i n g

R e

l i e f F i t t i n g ,

R e

t a i n i n

g B o

l t s T i g h t ,

R e

t a i n i n

g P l a t e a n

d F l a g

i n G o o

d C o n

d i t i o n ,

L u

b r i c a t

i o n

L i n e

i n G o o

d C o n

d i t i o n

G r e a s e

E x

i t i n g

R e


R e

t a i n i n g

B o

l t T i g

h t ,

R e

t a i n i n g

P l a t e i n

G o o

d C o n

d i t i o n ,

L u

b r i c a

t i o n

L i n e s

i n G o o

d C o n

d i t i o n

9 9 2 G

W H E E L L O A

D E R F R O N T L I N K A G E

D A I L Y W A

L K - A R O U N D

I N S P E C T I O N - L E F T S I D E




5/03

G r e a s e

E x

i t i n g

R e

l i e

f F i t t i n g ,

R e

t a i n i n g

B o

l t s T i g h t ,

R e

t a i n i n g

F l a g

i n G o

o d C o n

d i t i o n

G r e a s e

E x

i t i n g

B e

t w e e n

J o

i n t F a c e s ,

R e t a

i n i n g

B o

l t T i g h t ,

R e t a

i n i n g

P l a t e i n G o o

d C o n

d i t i o n

,

L u

b r i c a

t i o n

L i n e s

i n G o o

d C o n

d i t i o

n

G r e

a s e

E x

i t i n g

B e

t w e e n

J o

i n t F a c

e s ,

R e t a

i n i n g

B o

l t T i g h t ,

R e t a

i n i n g

F l a g s

i n G o o

d C o n

d i t i o n

,

L u b

r i c a

t i o n

L i n e s

i n G o o

d C o n

d i t i o

n

G r e a s e

E x

i t i n g

R e

l i e f F i t t i n

g ,

R e

t a i n i n g

B o

l t s T i g h t ,

R e

t a i n i n g

F l a g

i n G o o

d C o

n d i t i o n ,

L u

b r i c a

t i o n

L i n e s

i n G o o

d

C o n

d i t i o n

N o

G r e

a s e

E x

i t i n g

J o

i n t ,

L u

b r i c a

t i o n

L i n e

i n G o o

d C o n

d i t i o n ,

R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

P l a t e i n G o o

d C o n

d i t i o n

G r e a s e

E x

i t i n g

R e


R e

t a i n i n g

B o

l t T i g h t ,

R e

t a i n i n g

F l a g

i n G o o

d

C o n

d i t i o n

G r e a s e

E x

i t i n g

R e l

i e f F i t t i n g ,

R e

t a i n i n g

B o

l t T i g h

t ,

R e

t a i n i n g

F l a g

i n G

o o

d C o n

d i t i o n

G r e a s e

E x

i t i n g

R e


R e

t a i n i n g

B o

l t s T i g h t ,

R e

t a i n i n g

F l a g

i n

G o o

d C o n

d i t i o n A

G

Y

B

C E

F

K

9 9 2 G

W H E E L L O A D E R F R O N T

L I N K A G E

D A I L Y W A L K - A R O U N D I N S P E C T I O N - R I G H T S I D

E




5/03

9 9 2 G W H E E L L O A D E R

C O M P O N E N T R E P L A C E M E N T G U I D E L I N E S

• N e w P i n = N e w B e a r i n

g

• R e p l a c e B o t h t h e P i n a n d B e a r i n g W h e n G a l l i n g o r

M e t a l P i c k u p i s P r e s e n t o n E i t h e r P a r t

• R e p l a c e B o t h t h e P i n a n d B e a r i n g W h e n t h e

P i n D i a m e t e r H a s B e e n R e d u c e d b y M o r e T h a n 3

m m




5/03

9 9 2 G W H E E L L O A D E

R P I N J O I N T P R O B L E M P R O G R E S S I O N

P r o b l e m N o t e d

P o s s i b l e C a u s e

A c t i o n R e q u i r e d

R e s u l t I f N o t R e p a i r e d

B r o k e n L i n e o r F i t t i n g

B l o w n S e a l

N o G r e a s e E x i t

a t R e l i e f f i t t i n g

C r a c k e d o r B r o k e n F l a g

o r R e t a i n e r

H o t J o i n t

( 1 5 ° F T e m p . D i f f e r e n c e

B e t w e e n t h e B e a r i n g s )

N o i s y J o i n t

E x t e r n a l D a m a g e

R e p l a c e L i n e o r F i t t i n g

F a i l e d P i n a n d B e a r i n g

- H i g h G r e a s e P r e s s u r e

- B l o c k e d G r e a s e E x i t

- L i m i t G r e a s e P r e s s u r e t o

4 8 2 6 k P a ( 7 0 0 p s i )

- I n s t a l l N e w S e a l

F a i l e d P i n a n d B

e a r i n g

S t a r t o f P i n a n d B e a r i n g F a i l u r e

- J o i n t I n s p e c t i o n

- R e p a i r a s R e q u i r e d

- D a m a g e t o S t a t i c B o r e

- T o t a l J o i n t F a i l u

r e

- N o n P h o s p h a t e a n d O i l B o

l t

- I n c o r r e c t T o r q u e

- R e t a i n i n g P l a t e D o w e l s n o

t a

S l i p f i t i n P i n

- B e a r i n g W a l k i n g

- C h e c k d i m e n s i o n s a n d F i t s

- I n s t a l l N e w B o l t s w i t h C o r r e c t

T o r q u e P r o c e d u r e

- C o r r e c t A n y P r o b l e m s I d e n t i f i e d

C o n t i n u e d L o o s e

n i n g

a n d P i n F a i l u r e

S t a r t o f J o i n t F a i l u r e

S h u t D o w n a n d R e p a i r

T o t a l J o i n t F a i l u r e P o s s i b l y

R e q u i r i n g B o r e R

e p a i r

J o i n t F a i l u r e

S h u t D o w n a n d R e p a i r

T o t a l J o i n t F a i l u r e P o s s i b l y

R e q u i r i n g B o r e R

e p a i r

* A n y D a m a g e t o t h e B o r e o r

S p a c e r

D u r i n g B e a r i n g R e m o v a l M u s t b e

R e p a i r e d b e f o r e B e g i n n i n g

I n s t a l l a t i o n

R e m o v e A p p r o x i m a t e l y 2 / 3

o f t h e B e a r i n g T h i c k n e s s

i n F o u r L o c a t i o n s

9 9 2 G W H E E L L O A D E R

B E A R I N G

R E M O V A L G U I D E L I N E S



Documents

1.-Prácticas de Mantenimeinto