992G Wheel Loader Machine Systems Caterpillar

Removal Procedure

Start By:

1. Remove the bucket. Refer to Disassembly and Assembly, "Bucket - Remove".

2. Remove the tilt cylinder. Refer to Disassembly and Assembly, "Tilt Cylinder - Remove".

3. Remove the boom links. Refer to Disassembly and Assembly, "Boom Links - Remove".

4. Remove the bucket link. Refer to Disassembly and Assembly, "Bucket Link - Remove".

Illustration 1	g00863575

Note: Alignment of the pin joints is an important factor. The pins that are used in the pin joints are a slip fit. It is important to relieve the pin joint pressure from the pin joints that are being serviced. It is important to park the machine on a surface that is flat and level. Use the implement hydraulics, hoists, or suitable lifting devices in order to relieve the pin joint pressure. Use Illustration 1 as a guide for the pins and the pin joints that are referenced in this procedure.

Show/hide table

Illustration 2	g00421518

1. Place boom (1) on Tooling (A) at a height of 457 mm (18 inch), as shown.
   Show/hide table

   Illustration 3	g00421559

2. Use a suitable lifting device and a lifting sling to support lift cylinder (4). The weight of the lift cylinder is approximately 1035 kg (2280 lb).

3. Remove bolt (2), the washer, and the spacer from plate (3).
   Show/hide table

   Illustration 4	g00863582

4. Install Tooling (B) in the threaded holes of plate (3). Tighten Tooling (B) evenly in order to remove plate (3). Remove the two dowel pins.
   Show/hide table

   Illustration 5	g00863750

5. Remove O-ring seal (5) from the face of the L-pin (6).
   Show/hide table

   Illustration 6	g00863752
   Right Side

6. Remove bolt (8), the washer, and spacer (7) from plate (9).

7. Remove plate (9).
   Show/hide table

   Illustration 7	g00692942
   Right Side

8. Remove maintenance free linkage seal (10) from plate (9).
   Show/hide table

   Illustration 8	g00692944
   Right Side

9. Remove plate (11) from L-pin (7).

10. Remove O-ring seal (12) from L-pin (7).
    Show/hide table

    Illustration 9	g00863753

11. Attach a hoist and a suitable lifting sling to Tooling (C). The weight of Tooling (C) is 215 kg (475 lb). Install Tooling (C) on the head end of the L-pin. Use Tooling (C) to pull out the L-pin enough in order to free the bore of lift cylinder (4).
    Show/hide table

    Illustration 10	g00421858

12. Lower lift cylinder (4) onto cribbing, as shown.
    Show/hide table

    Illustration 11	g00863756

13. Attach chains and a suitable lifting device to lift cylinder (13) before you pull out the remainder of L-pin (7). The weight of the lift cylinder is 1035 kg (2280 lb).

14. Tooling (C) will retain L-pin (7) when the pin is removed. The weight of the L-pin is 295 kg (650 lb). The combined weight of Tooling (C) and of L-pin (7) is 510 kg (1125 lb).
    Show/hide table

    Illustration 12	g00693195

15. Lower lift cylinder (13) onto cribbing, as shown.
    Show/hide table

    Illustration 13	g00693196

16. Remove clamps (15) that secure wiring harness (14) to boom (1). Place wiring harness (14) aside.
    Show/hide table

    Illustration 14	g00422003

    Note: The weight of the boom that is used in this lift arrangement is 5993 kg (13180 lb).

17. Use a hoist and a suitable lifting sling to support boom (1). The weight of the boom is 5650 kg (12450 lb). Raise boom (1) enough in order to remove Tooling (A).
    Show/hide table

    Illustration 15	g00422011

18. Lower boom (1) to a height of approximately 25 mm (1 inch) above the ground.
    Show/hide table

    Illustration 16	g00693206

    Note: The following steps are for the removal of the H-pin. The H-pin is located in the upper frame.

19. Remove bolt (16) and the washer from plate (17).
    Show/hide table

    Illustration 17	g00863755

20. Install Tooling (B) in the threaded holes of plate (17). Tighten Tooling (B) evenly in order to remove plate (17). Remove the two dowel pins.
    Show/hide table

    Illustration 18	g00863799

21. Remove O-ring seal (18) from the face of H-pin (19).
    Show/hide table

    Illustration 19	g00863805

22. Disconnect the harness for the right headlamps. The electrical connector is located under the fender.

23. Remove four bolts (21) and headlamp (20) from the right fender.
    Show/hide table

    Illustration 20	g00863806

24. Remove four bolts (22), the washers and plate (23) from the head end of H-pin (19).
    Show/hide table

    Illustration 21	g00863808

25. Attach a hoist and a suitable lifting sling to Tooling (D). The weight of Tooling (D) is 213 kg (470 lb). Install Tooling (D) in order to remove the H-pin.

26. Tooling (D) will retain the H-pin when the H-pin is removed. The weight of the H-pin is 209 kg (460 lb). The combined weight of Tooling (D) and of the H-pin is 420 kg (925 lb).
    Show/hide table

    Illustration 22	g00422399

    Show/hide table

    Illustration 23	g00422401

    Note: The weight of the boom in this lift arrangement is 5993 kg (13212 lb).

27. Carefully remove boom (1). The weight of the boom is 5650 kg (12456 lb).
    Show/hide table

    Illustration 24	g00863832

28. Remove collar (24) from the frame. The collar is a slip fit in the H-pin bore. Remove the remaining collar assembly on the opposite side of the machine.
    Show/hide table

    Illustration 25	g00863833

29. Remove seal assembly (25) from each side of collar (24). Remove the seal assemblies from the remaining collar.
    Show/hide table

    Illustration 26	g00863838

    Note: The following steps are for the removal of bearings (26) at the four pin joints of boom (1).

    Show/hide table

    Illustration 27	g00863856

30. Assemble Tooling (E). The bearing plate will rotate enough in order to allow insertion through the inside diameter of the bearing that is being removed.

31. The bearing plate will then rotate into position after the bearing plate has passed through the inside diameter of the bearing.

32. The following steps are for preparing the bearing for removal.
    Show/hide table

    Illustration 28	g00565676

    Note: Before the bearing is removed, use air arc gouging or a torch gouging tip in order to remove material. Do not allow the air arc gouging to damage the bore. This can create high spots under the bearing or a leak path.

    1. Cut approximately 3/4 of the way through the bearing in four locations. See Illustration 28. This will relax the bearing. Minimum force will then be required in order to pull the bearing .

    2. Allow the bearing to reach ambient temperature before removal.
    Show/hide table

    Illustration 29	g00863877

    Show/hide table

    Illustration 30	g00863878

33. Use a hoist and a suitable lifting sling to support Tooling (E). The weight of Tooling (E) is 159 kg (350 lb). Mount Tooling (E) in place on the rear side of bearing (27).

34. Remove bearing (27) from the boom bore.

35. Repeat Steps 32 through 34 in order to remove the bearings from the opposite side of the boom.
    Show/hide table

    Illustration 31	g00422820
    H-pin Bore

36. Remove spacer (28) from the H-pin bore of the boom. The spacer is a slip fit inside the H-pin bore. The weight of spacer (28) is 18 kg (40 lb).

    Note: Use the same procedure for the remaining pin joints. The weight of the bearing spacer in the L-pin joint is 34 kg (75 lb). Use a hoist and a suitable lifting sling to remove the spacer.

37. If the bores in the boom are damaged, perform the following procedures:

    • Perform a repair weld on any gouges.

    • Use the die grinder to repair the welds.

    • Use a die grinder to grind any high spots.
    Show/hide table

    Illustration 32	g00863879

38. Remove seal assemblies (29) from lift cylinder (4). Repeat this step for the remaining lift cylinder.