Routine Inspection of Certain Wheel Loader Heavy Structures {0374, 0679, 5063, 6107, 6118, 6119, 6513, 7051, 7069} Caterpillar

Wheel Loader

986H (S/N: L8S1-UP)

986K (S/N: MH81-UP; NL81-UP; SWH1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP; EWX1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990H (S/N: BWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

Introduction

Routine Inspection of Wheel Loader heavy structures promotes machine safety and productivity.

Large Wheel Loader Heavy Structures Areas to Inspect

Certain 986H, 988K and 990K Wheel Loader heavy structure assemblies require inspection at least every 500 hours of service. The structures to be inspected include the non-engine end frame (NEEF), engine end frame (EEF), lift arm and bucket link. Proper inspection intervals ensure that critical machine structures continue to meet performance expectations.

Any cracks found during these inspections must be chamfered out and welded promptly, as part of normal maintenance. Follow Special Instruction, REHS1841, "General Welding Procedures".

The illustrations in the sections below highlight the welded joints that require routine inspection.

986H Wheel Loader Heavy Structures

Illustration 1	g03856416
Inspect the welds in these areas, both sides of the frame (Non-engine End Frame). Inspect the window plate (A), for cracks.

Illustration 2	g03856419
Inspect the welds in these areas on both sides of the frame, top and bottom sides of the plates (Non-engine End Frame).

Illustration 3	g03856420
Inspect the welds in these areas, both sides of the frame (Non-engine End Frame).

Illustration 4	g03856424
Inspect the welds in these areas, both sides of the frame (Engine End Frame). Inspect the welds around the steering casting, both sides of the frame. Inspect the hitch boss welds and hitch plate welds on both hitches.

Illustration 5	g03856430
Inspect the welds around the crossmember (Engine End Frame). Inspect the welds around the front trunnion mount gusset on both sides of the frame. Inspect the welds on the ends of lower hitch, both sides of the frame.

Illustration 6	g03856434
Inspect the welds on the inside steering bracket casting, both sides of the frame (Engine End Frame). Inspect the welds around the ends of upper hitch on both sides of the frame, and between hitch. Inspect the weld toe on top of the lower hitch plate.

Illustration 7	g03856435
Inspect the welds around these bosses, inside, and outside of the plate, both sides of the lift arm.

Illustration 8	g03856437
Inspect the welds around the cross member on both sides of the lift arm.

Illustration 9	g03856438
Inspect the welds around the bosses on both sides of the bucket link.

988K Wheel Loader Heavy Structures

Illustration 10	g06344724
Inspect these welds, both sides of the frame. (Non-engine End Frame)

Illustration 11	g06344140
Inspect these welds, both sides of the frame. (Non-engine End Frame)

Illustration 12	g03850063
Inspect these welds, both sides of the frame. (Non-engine End Frame)

Illustration 13	g03850064
Inspect these welds, both sides of the frame. (Non-engine End Frame)

Illustration 14	g03850065
Inspect the welds around the steering casting, both sides of the frame. (Engine End Frame) Inspect hitch boss welds and hitch plate welds on both hitches.

Illustration 15	g03850066
Inspect the welds around the cross member. (Engine End Frame) Inspect the welds around the front trunnion mount gusset, both sides of the frame. Inspect the welds on the ends of lower hitch, both sides of the frame.

Illustration 16	g03850067
Inspect the welds around the ends of upper hitch, both sides of the frame, and between hitch. (Engine End Frame). Inspect the welds on the inside of the steering bracket casting, both sides of the frame.

Illustration 17	g03850068
Inspect the welds around these bosses, inside, and outside of the plate, both sides of the lift arm.

Illustration 18	g03850069
Inspect the welds around the cross member on both sides of the lift arm.

Illustration 19	g03850070
Inspect the welds around the bosses on both sides of the bucket link.

990K Wheel Loader Heavy Structures

Illustration 20	g03848550
Inspect the four corners of the window plate. (Non-engine End Frame)

Illustration 21	g03848551
Inspect these areas for fatigue. (Non-engine End Frame)

Illustration 22	g03848553
Inspect this area, both sides of the frame. (Non-engine End Frame)

Illustration 23	g03848554
Inspect this area, both sides of the frame. (Non-engine End Frame)

Illustration 24	g03848555
Inspect these areas, both sides of the frame. (Non-engine End Frame)

Illustration 25	g03848556
Inspect this area, both sides of the frame. (Non-engine End Frame)

Illustration 26	g03848557
Inspect the hitch boss welds and the hitch plate welds on both hitches. (Engine End Frame) Inspect the welds around the steering casting and oscillation stops, both sides of the frame.

Illustration 27	g03848558
Inspect the welds around the cross member. (Engine End Frame) Inspect the welds around the oscillation stops, both sides of the frame. Inspect the welds on the ends of lower hitch, both sides of the frame.

Illustration 28	g03848562
Inspect the welds on the top and sides of the front trunnion mount casting, both sides of the frame. (Engine End Frame) Inspect the welds on the inside steering castings, both sides of the frame. Inspect the welds on the front of the lower hitch.

Illustration 29	g03848563
Inspect the welds between upper hitch and butterfly plate. (Engine End Frame)

Illustration 30	g03848565
Inspect the welds at this location on both sides of the lift arm.

Illustration 31	g03849815
Inspect the welds on the front and back sides of the cross member, both left and right sides of the lift arm. Inspect the tab weld and the tab radius on the casting for both sides of the lift arm.

Illustration 32	g03849816
Inspect the welds around the bosses on both sides of the bucket link.