992G Wheel Loader Machine Systems Caterpillar

Installation Procedure

Illustration 1	g00686497

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 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 pressure. Use Illustration 1 as a guide for the pins and the pin joints that are referenced in this procedure.

Note: If new pins are being installed, refer to Disassembly and Assembly, "Bucket - Install" for the break-in procedure.

Note: Using the correct seal installation tools is the preferred method for assembling the seal assembly and for installing the seal assembly. Refer to Disassembly and Assembly, "Maintenance Free Linkage Seals - Install" for the correct procedure.

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Illustration 2	g00422823

1. Use Tooling (C) to install seal assembly (29) in the seal groove of lift cylinder (8). Refer to Disassembly and Assembly, "Maintenance Free Linkage Seals - Install" for the correct procedure.

2. Repeat Step 1 for the remaining lift cylinder.

   Note: Steps 3 through 6 are for installing the boom bearings.

3. Thoroughly clean the bores and the oil reservoirs of the boom prior to installation.
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   Illustration 3	g00423980

4. Install bearing spacer (28) in the pin bore of boom (1). The spacer is a slip fit inside the pin bore. The weight of spacer (28) is approximately 18 kg (40 lb).

   Note: Use the same procedure for the remaining pin joints. The weight of the bearing spacer that is used in the pin bore of the boom is approximately 34 kg (75 lb). Use a suitable lifting device to remove the spacer.

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   Illustration 4	g00423999

5. Use insulated gloves to handle bearing (27). Lower the temperature of bearing (27) to −73°C (−100°F) prior to installation. Use a suitable lifting device to support Tooling (B). The weight of Tooling (B) is approximately 125 kg (275 lb).

   Note: Make sure that the "2.0 Offset - Face A" side of the 138-0603 Plate is facing toward bearing (27). Make sure that the "Bearing Bore - Face E" side of 138-0992 Adapter Plate is facing toward the left pin bore.

6. Use Tooling (B) to install bearing (27) in the right side of the pin bore. Leave Tooling (B) in place on the right side of boom in order to install the remaining bearing (27) on the left side.
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   Illustration 5	g00693553

7. Use insulated gloves to handle bearing (27). Lower the temperature of bearing (27) to −73°C (−100°F) prior to installation.

   Note: Turn the 138-0992 Adapter Plate so that the "Bearing I.D. - Face F" side is positioned toward bearing (27).

8. Use Tooling (B) to install bearing (27) in the left side of the pin bore. Press the bearing until both bearings are contacting the bearing spacer.

   Note: There should be no gap between the spacer and the bearings. The spacer sets the width of the pin joint.

9. Remove Tooling (B).

10. Use the same procedure for the installation of the remaining three boom bearings.

    Note: The following steps are for the installation of the boom.

    Note: Using the correct seal installation tools is the preferred method for assembling the seal assembly and for installing the seal assembly. Refer to Disassembly and Assembly, "Maintenance Free Linkage Seals - Install" for the correct procedure.

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    Illustration 6	g00693273

11. Use Tooling (C) to install seal assembly (26) in the seal groove of collar (25). Refer to Disassembly and Assembly, "Maintenance Free Linkage Seals - Install" for the correct procedure. Repeat this step for the opposite side of collar (22).

12. Repeat Steps 11 through 12 for the assembly of the remaining collar.
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    Illustration 7	g00693272

    Note: The outside diameter of the collar is a slip fit in the pin bore.

13. Thoroughly clean the upper frame pin bores. Lubricate the bores with Tooling (F). Install collar assembly (25) in the right side of the loader frame. DO NOT install a collar assembly in the left side of the loader frame at this time.

    Note: The collar should extend from the frame bore by 13 mm (0.50 inch). This will allow enough clearance in order to install the boom.

14. Lubricate the inside diameter of the collar assembly and the upper boom bores with Tooling (G).
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    Illustration 8	g00422401

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    Illustration 9	g00422399

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

15. Use a suitable lifting device to support boom (1). The weight of boom (1) is approximately 5650 kg (12456 lb).
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    Illustration 10	g00693599

    Note: Pin (20) is a slip fit in the bore. Proper alignment of the bores is important. Do not use excessive force to install pin (20).

16. Lubricate pin (20) with Tooling (G). Install the boom pin through the frame and into the boom.
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    Illustration 11	g00693211

17. Make sure that the head end of pin (20) is installed into the slot. Install plate (24), the washers and four bolts (23).
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    Illustration 12	g00693210

18. Install headlamps (21), the washers and four bolts (22) on the front fender. Connect the electrical connector for the headlamps.
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    Illustration 13	g00693209

19. Lubricate the inside diameter of the collar assembly with Tooling (G).

20. Install the remaining collar assembly (25) in the pin bore on the left side of the loader frame.

21. Install O-ring seal (19) in the groove of A-pin (20). The groove is located on the left side of machine.
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    Illustration 14	g00693206

22. Align plate assembly (17) with dowel holes in the end of upper boom pin. The two fill ports in plate assembly (17) should be located on the upper portion of the pin diameter. Use the washer and bolt (16) to secure plate (17) to the pin. Tighten bolt (16) to a torque of 600 ± 80 N·m (443 ± 60 lb ft). Turn bolt (16) by an additional 45 degrees.
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    Illustration 15	g00422003

23. Rest boom (1) on Tooling (A) at a height of 457 mm (18 inch) above the ground.
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    Illustration 16	g00693196

24. Install wiring harness (14) and clamps (15) to the boom.
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    Illustration 17	g00424283

25. Lubricate the bore of tilt cylinder (8) and the bore of boom (1) with Tooling (G). Use a suitable lifting device to raise lift cylinder (8) and align the bearing bores of the boom and of the lift cylinder. The weight of the lift cylinder is approximately 1035 kg (2280 lb).

    Note: Do not damage seal assemblies that were installed in Step 1.

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    Illustration 18	g00693604

26. Lubricate pin (7) with Tooling (G). Use a suitable lifting device to install pin (7) through the cylinder bores and into the boom bores. The weight of the pin (7) is approximately 295 kg (650 lb).

    Note: pin (7) should not be installed completely until the left cylinder is in place.

    Note: pin (7) is a slip fit into the bores. Proper alignment of the bores is important . Do not use excessive force to install pin (7).

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    Illustration 19	g00421858

27. Lubricate the bore of lift cylinder (4) with Tooling (G). Use a suitable lifting device to raise lift cylinder (4) and align the bearing bores of the boom and of the lift cylinder. The weight of the lift cylinder is approximately 1035 kg (2280 lb).

    Note: Do not damage the seal assemblies that were installed in Step 1.

28. Install the remaining portion of pin (7) in the bearing bore of lift cylinder (4).
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    Illustration 20	g00692944
    Right Side

29. Install O-ring seal (12) in pin (7).

    Note: Rotate the pin in order to properly orient the flag of plate (11), as shown.

30. Install plate (11) on pin (7).
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    Illustration 21	g00692942
    Right Side

31. Use Tooling (C) to install maintenance free linkage seal (10) in plate (9). Refer to Disassembly and Assembly, "Maintenance Free Linkage Seals - Install" for the correct procedure.
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    Illustration 22	g00692940
    Right Side

32. Install plate (9).
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    Illustration 23	g00692939
    Right Side

33. Install the spacer, the washer, and bolt (8) on plate (9). DO NOT torque bolt (8) at this time.
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    Illustration 24	g00421699

34. Install the O-ring seal (6) in the groove of K-pin (7).
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    Illustration 25	g00421559

35. Align the dowels in plate assembly (3) with the dowel holes in the end of the lift cylinder pin. The two fill ports in the plate assembly should be located on the upper portion of the pin diameter. Use bolt (2) to secure plate (3) to the lift cylinder pin.

36. Use Tooling (E) to tighten bolt (2). The torque for bolt (2) is 2700 ± 300 N·m (1985 ± 220 lb ft).

37. Use Tooling (E) to tighten bolt (8). The torque for bolt (8) is 2700 ± 300 N·m (1985 ± 220 lb ft).
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    Illustration 26	g00699028

38. Use the following procedure to test maintenance free linkage seals for correct assembly:

    1. Install Tooling (D) to the top fill port of the pin.

    2. Apply 689 kPa (100 psi) of air pressure to the top fill port of the pin.

    3. Monitor the pressure for ten minutes.

    4. The pressure should not drop more than 69 kPa (10 psi) if the K-pin joint is assembled correctly.

39. Repeat Step 38 in order to test the A-pin joint.

End By:

1. Install the tilt cylinder. Refer to Disassembly and Assembly, "Tilt Cylinder - Install".

2. Install the boom links. Refer to Disassembly and Assembly, "Boom Links - Install".

3. Install the bucket links. Refer to Disassembly and Assembly, "Bucket Links - Install".

4. Install the bucket. Refer to Disassembly and Assembly, "Bucket - Install".