Installation Procedure for Secondary Pin Retention System on Wheel Loaders{6107, 6118} Caterpillar

Wheel Loader:

992G (S/N: 7HR1-UP; AZX1-792; ADZ1-UP)

Introduction

This Special Instruction contains two procedures to be performed on the boom of the 992G Wheel Loader:

• Installation of the axial retention pin for the B-pin

• Installation of the axial retention pin for the A-pin

An axial retention pin is installed in order to prohibit lateral movement of the cartridge. The two procedures are basically the same procedure except for a few minor changes.

The procedures are adaptable to the machines that are listed above.

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the buckets or implements (loader and backhoe) and stabilizers to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

Preparing the Area for Welding

Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.

• Oil

• Grease

• Paint

• Dirt

If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the weld splatter.

Proper Welding Procedure on Machines and Engines with Electronic Controls

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the following steps:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This will reduce the chance of damage from welding current to the following components: bearings, hydraulic components and electrical components.

   Note: Do not use electrical components as a ground point for the welder. Do not use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Tooling

Use the following contact for inquiries regarding the fixtures and tooling that may be used in order to perform the following procedures:

Procedure to Install the Cartridge Retainer for the B-Pin Joint

Machining the Boom

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Illustration 1	g01431654
(1) 76.2 mm (3 inch) diameter through hole (2) 152.4 mm (6 inch) spotface (3) Four tapped holes (12 mm X 1.5 at a depth of 21 mm) (B) 15 mm (0.6 inch) (C) 400 ± 2 mm (15.75 ± 0.08 inch) (D) 800 ± 2 mm (31.5 ± 0.08 inch)

1. Measure the distance between the outside faces of the boom. The nominal distance is 800 ± 2 mm (31.5 ± 0.08 inch).

2. Center the 76.2 mm (3 inch) hole and the 152.4 mm (6 inch) spot face between the two outside faces. The nominal distance from each face will be 400 ± 2 mm (15.75 ± 0.08 inch).

   Note: The 76.2 mm (3 inch) hole and the spotface must be perpendicular to the bore and the surface of the boom.

   Note: The location of the 76.2 mm (3 inch) hole will control the centering of the cartridge and the boom in the frame so it is important to get the hole centered on the boom.

3. The hole must intersect the center line of the bore in order to ensure that the retainer has the proper engagement with the cartridge. See Section A-A in Illustration 1.

4. Once the retainer hole has been laid out, bore the retainer hole.

5. After you drill the hole, remove any burrs in the bore that may interfere with the installation of the new cartridge.

6. Machine a spotface on the hole. The spotface must be a 152.4 mm (6 inch) diameter. The depth of the spotface surface should be 15 mm (0.6 inch) at the high side of the boom. See Section A-A in Illustration 1.

7. Drill and tap four 12M X 1.75 holes (3). The holes are for the 8T-4956 Bolts that are used for the installation of the 281-7166 Plate (cover plate).

   Note: Use the cover plate as a template for the placement of the holes.

Installing the Cartridge

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Illustration 2	g01431672
(4) 314-6764 Cartridge

1. Install 314-6764 Cartridge (4). The new cartridge has a groove on the outside diameter. The 281-7164 Retainer will fit into the groove. See the inset in Illustration 2. The retainer may be used in order to center the cartridge in the boom.

   ReferenceRefer to Special Instruction, REHS2648, "Procedure to Replace Loader Linkage Pins on Wheel Loaders" for the installation procedure of the 314-6764 Cartridge .

Installing the Retainer and the Shims

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Illustration 3	g01431670
(5) 139-4267 Shims (6) 139-6380 Shims (7) 281-7164 Retainer

1. Install retainer (7) so that the retainer fits into the groove of the cartridge. Verify that the retainer is fully seated into the groove of the cartridge.

2. Install 139-6380 Shims (6) and 139-4267 Shims (5) in order to create a gap that is 1 mm (0.039 inch) or less between the shims and cover plate (10). See Illustration 4 and Illustration 4.

Installing the Cover Plate

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Illustration 4	g01431846
(7) 281-7164 Retainer (8) Four 8T-4956 Bolts (9) Four 8T-4223 Hard Washers (10) 281-7166 Plate (cover plate) (11) The retainer must be fully seated in the groove of the cartridge. (E) Gap between the shims and cover plate (1 mm (0.039 inch) or less)

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Illustration 5	g01431847
Finished view

1. Install 2H-4145 O-Ring Seal into 281-7166 Plate (10). Install cover plate (10) .

2. Install four 8T-4956 Bolts (8) and 8T-4223 Hard Washers (9) .

Centering the Boom

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Illustration 6	g01431849
(12) Bolts (13) 246-6613 Plate (Cover plate) (14) Bucket flange (F) The dimension is typically 10 mm (0.39 inch). During installation of the cartridge, the dimension will be 20 mm (0.79 inch). (G) The dimension is typically 10 mm (0.39 inch). During installation of the cartridge, the boom will be against the bucket flange.

1. Install 246-6613 Plate (13) with several cover plate bolts (12). Use bolts (12) in order to pull the boom so that the boom is evenly centered between bucket flanges (14). When the boom is centered, the gap between the boom and the bucket flange is nominally 10 mm (0.39 inch). After the boom is centered, remove the 246-6613 Plate (13) .

   Note: During the installation of the cartridge, the cartridge will typically pull against the left hand side of the bucket.

Shimming the Cartridge

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Illustration 7	g01431850
(H) When the boom is centered, the gap between the boom and the bucket flange is nominally 10 mm (0.39 inch). (15) Insert (16) End of cartridge

1. Check the distance between end (16) of the cartridge and insert (15). Nominally, the dimension on each side of the boom should be the same dimension, but the dimension may vary. The variation depends on the centering of the cartridge to the boom.

2. End (16) of the cartridge should not stick out past the face of insert (15). If one end sticks out past the insert, the boom must be adjusted so that neither end sticks out.

   Note: If adjusting the boom does not solve the problem, the 76.2 mm (3 inch) retainer hole was not correctly located in the center of the boom.

3. Measure distance (J) and (K) between ends (16) of the cartridge and the faces of insert (15).

4. Install shims that are equal to dimension (J). Add an additional 0.5 mm (0.02 inch) to 1 mm (0.04 inch) to the shim thickness. Install shims that are equal to dimension (K). Add an additional 0.5 mm (0.02 inch) to 1 mm (0.04 inch) to the shim thickness.

   Use the following shims:

   • 272-8140 Plate equals 0.8 mm (0.032 inch).

   • 246-6629 Plate equals 1.6 mm (0.063 inch).

   • 262-7885 Plate equals 5 mm (0.197 inch).

Installing the Cover Plates on the Cartridge Assembly

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Illustration 8	g01432079

1. Install cover plates (13) onto each end of the cartridge. Verify minimum gap (L) between cover plate (13) and insert (15). Gap (L) should be 0.5 mm (0.02 inch) to 1 mm (0.04 inch).

Procedure to Install the Cartridge Retainer for the A-Pin Joint

The procedure that is used to install the axial retention pin for the A-pin differs slightly from the procedure that is used for the B-pin. The differences are noted below:

• A 281-7165 Boss is welded onto the spotface surface of the retainer hole. The boss has premachined tapped holes for the cover plate.

• A 281-7167 Spacer is installed with the 281-7164 Retainer . The spacer is used with the 281-7165 Boss .

Machining the Boom

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Illustration 9	g01433042
(1) 76.2 mm (3 inch) diameter through hole (2) 152.4 mm (6 inch) (diameter of the spotface) (B) 15 mm (0.6 inch) (C) 400 ± 2 mm (15.75 ± 0.08 inch) (D) 800 ± 2 mm (31.5 ± 0.08 inch)

1. Measure the distance between the outside faces of the boom. The nominal distance is 800 ± 2 mm (31.5 ± 0.08 inch).

2. Center the 76.2 mm (3 inch) hole and the 152.4 mm (6 inch) spot face between the two outside faces. The nominal distance from each face will be 400 ± 2 mm (15.75 ± 0.08 inch).

   Note: The 76.2 mm (3 inch) hole must be perpendicular to the bore of the A-pin and the surface of the boom.

   Note: The location of the 76.2 mm (3 inch) hole will control the centering of the cartridge and the boom in the frame so it is important to get the hole centered on the boom.

3. The hole must intersect the center line of the bore in order to ensure that the retainer has the proper engagement with the cartridge. See Section A-A in Illustration 9.

4. Once the location for the retainer hole has been laid out, bore the retainer hole.

5. After the hole is drilled, remove any burrs in the bore that may interfere with the installation of the new cartridge.

6. Machine a spotface on the hole. The spotface must be a 152.4 mm (6 inch) diameter. The depth of the spotface surface should be 15 mm (0.6 inch) at the high side of the boom. See Section A-A in Illustration 9.

Installing the 281-7165 Boss

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Illustration 10	g01433063
(17) 281-7165 Boss (N1) Welding which uses mild steel, low hydrogen filler metals which include welding electrodes for shielded metal arc welding (W8) 8 mm (0.31 inch) fillet weld

1. Before installing 281-7165 Boss (17), make sure that the spotface is clean and free of debris.

2. Install 281-7165 Boss (17). Weld an 8 mm (0.31 inch) fillet weld around boss (17) .

Installing the Cartridge

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Illustration 11	g01433071
(4) 314-6764 Cartridge

1. Install 314-6764 Cartridge (4). The new cartridge has a groove on the outside diameter. The 281-7164 Retainer will fit into the groove. See the inset in Illustration 11. The retainer may be used in order to center the cartridge in the boom.

   ReferenceRefer to Special Instruction, REHS2648, "Procedure to Replace Loader Linkage Pins on Wheel Loaders" for the installation procedure of the 314-6764 Cartridge .

Installing the Retainer and the Shims

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Illustration 12	g01433074
(5) 139-4267 Shims (6) 139-6380 Shims (7) 281-7164 Retainer (18) 281-7167 Spacer

1. Install retainer (7) so that the retainer fits into the groove of the cartridge. Verify that the retainer is fully seated into the groove of the cartridge.

2. Install 281-7167 Spacer (18). Install 139-6380 Shims (6) and 139-4267 Shims (5) in order to create a gap that is 1 mm (0.039 inch) or less between the shims and cover plate (10) .

Installing the Cover Plate

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Illustration 13	g01433076
(7) 281-7164 Retainer (8) Four 8T-4956 Bolts (9) Four 8T-4223 Hard Washers (10) 281-7166 Plate (cover plate) (11) The retainer must be fully seated in the groove of the cartridge. (18) 281-7167 Spacer (E) Gap between the shims and cover plate (1 mm (0.039 inch) or less)

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Illustration 14	g01433077
Finished view

1. Install 2H-4145 O-Ring Seal into 281-7166 Plate (10). Install cover plate (10). Gap (D) that is between the cover plate and the shims should be 1 mm (0.04 inch) or less.

2. Install four 8T-4956 Bolts (8) and 8T-4223 Hard Washers (9) .

Centering the Boom

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Illustration 15	g01433291
(12) Bolts (13) 246-6613 Plate (Cover plate) (19) Frame plates (F) The dimension is typically 10 mm (0.39 inch). During installation of the cartridge, the dimension will be 20 mm (0.79 inch). (G) The dimension is typically 10 mm (0.39 inch). During installation of the cartridge, the boom will be against the frame plate.

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Illustration 16	g01433079
(H) The dimension is typically 10 mm (0.39 inch).

1. Install 246-6613 Plate (13) with several cover plate bolts (12). Use bolts (12) in order to pull the boom so that the boom is evenly centered between frame plates (19). Gap (H) will be approximately 10 mm (0.39 inch) when the boom is centered between frame plates (19) .

   Note: During the installation of the cartridge, the cartridge will typically pull against the left hand side of the frame.

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Illustration 17	g01433120

2. After the cartridge is centered, remove the 246-6613 Plate (13). Check the distance between the end (16) of the cartridge and the insert (15). Nominally, the dimension on each side of the boom will be the same dimension, but the dimension may vary. The variation depends on the centering of the cartridge to the boom.

3. The end (16) of the cartridge should not stick out past the face of the insert (15). If one end sticks out past the insert, the boom must be adjusted so that neither end sticks out.

   Note: If adjusting the boom does not solve the problem, the 76.2 mm (3 inch) retainer hole was not correctly located in the center of the boom.

Shimming the Cartridge

1. Measure distance (J) between ends (16) of the cartridge and the faces of insert (15) in the frame. Perform the same measurement on the other end of the cartridge.

2. Install shims that are equal to dimension (J). Add an additional 0.5 mm (0.02 inch) to 1 mm (0.04 inch) to the shim thickness.

3. Install the necessary shims that are equal to the measurement on the other end of the cartridge. Add an additional 0.5 mm (0.02 inch) to 1 mm (0.04 inch) to the shim thickness.

   Use the following shims:

   • 272-8140 Plate equals 0.8 mm (0.032 inch).

   • 246-6629 Plate equals 1.6 mm (0.063 inch).

   • 262-7885 Plate equals 5 mm (0.197 inch).

Installing the Cover Plates on the Cartridge Assembly

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Illustration 18	g01433122

1. Install cover plates (13) onto each end of the cartridge. Verify the minimum gap between the cover plate and the insert. The distance should be 0.5 mm (0.02 inch) to 1 mm (0.04 inch) for both the left side and the right side.