1.-prácticas de mantenimeinto
TRANSCRIPT
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Service Training SERV1770
Meeting Guide 770 May 2003
TECHNICAL PRESENTATION
992G WHEEL LOADER
BEST MAINTENANCE PRACTICES
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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.
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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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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.
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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 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.
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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).
1
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.
1
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
4
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.
1
3
2
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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.
1
2
3
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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).
1
2
4
3
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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
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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
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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.
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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.
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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.
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* 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.
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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.
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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.
NOTE: Refer to REHS1501 for additional information regarding the
break in procedure for the pin joints.
NOTE: Refer to TIBU3641 for additional information regarding the
daily walk-around inspection for the pin joints.
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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.
NOTE: Refer to REHS1501 for additional information regarding the
break in procedure for the pin joints.
NOTE: Refer to TIBU3641 for additional information regarding the
daily walk-around inspection for the pin joints.
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CONCLUSION
The 992G Wheel Loader linkage will provide the expected service life
when it is serviced and maintained correctly.
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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
_____ No damaged or missing parts
Left end of the K pin
_____ Retaining plate in good condition
_____ Retaining bolt tight
_____ No grease exiting the joint
_____ Lubrication lines in good condition
Left End of the E Pin
_____ Retaining plate and flag in good condition
_____ Retaining bolts tight
_____ Grease exiting the joint
_____ Lubrication lines in good condition
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Left End of the F Pin
_____ Retaining plate and flag in good condition
_____ Retaining bolts tight
_____ Grease exiting the relief fitting
Left End of the B Pin
_____ Retaining plate in good condition
_____ Retaining bolt tight
_____ Grease exiting the relief fitting only
_____ Lubrication lines in good condition
Left End of the C Pin
_____ Retaining plate in good condition
_____ Retaining bolt tight
_____ Grease exiting the pin joint
_____ Lubrication lines in good condition
Lines, hoses, and injectors under the bucket tilt link
_____ No leaks
_____ No damaged or missing parts
Forward of the Right Front Tire
Right end of the B pin
_____ Retaining plate and flag in good condition
_____ Retaining bolts tight
_____ Grease exiting the relief fitting only
_____ Lubrication lines in good condition
Right end of the C pin
_____ Retaining plate and flag in good condition
_____ Retaining bolts tight
_____ Grease exiting the pin joint
_____ Lubrication lines in good condition
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STMG 770 - 30 - Student Handout 1
5/03
A
G
Y
B C
E
F
K
G r e a s e
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B e
t w e e n
J o i n
t F a c e s ,
R e
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R e
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L u
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L i n e s
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R e
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R e
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L u
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,
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d i t i o n ,
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R e
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t a i n i n
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R e
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b r i c a t
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G r e a s e
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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
P l a t e i n
G o o
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d i t i o n ,
L u
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L i n e s
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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
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I N S P E C T I O N - L E F T S I D E
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STMG 770 - 31 - Student Handout 2
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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
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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
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e s ,
R e t a
i n i n g
B o
l t T i g h t ,
R e t a
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F l a g s
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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
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d i t i o
n
G r e a s e
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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
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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
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d
C o n
d i t i o n
N o
G r e
a s e
E x
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J o
i n t ,
L u
b r i c a
t i o n
L i n e
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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
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
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d
C o n
d i t i o n
G r e a s e
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9 9 2 G
W H E E L L O A D E R F R O N T
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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
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STMG 770 - 32 - Student Handout 3
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
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g
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m m
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STMG 770 - 33 - Student Handout 4
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
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B e t w e e n t h e B e a r i n g s )
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T o r q u e P r o c e d u r e
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n i n g
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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
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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
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