Procedure to Install Grease Line in the Front Lines Group on Certain 980M and 982M Wheel Loaders {7510, 7540} Caterpillar

Wheel Loader

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

Introduction

This Special Instruction contains the parts and procedure to install grease line in the front lines group on machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Show/hide table

Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Show/hide table

Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Show/hide table

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.

Show/hide table

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

Rework Procedure for 980M Wheel Loaders

Required Parts

Show/hide table

Illustration 1	g06100827
(A) Front Lines Group

Show/hide table

Illustration 2	g06097548
View of area A (B) 389-4330 Hose As (C) 252-8211 Sleeve (D) 389-4329 Hose As (E) 389-4328 Hose As

1. Remove hose assembly (B), hose assembly (D), hose assembly (E), and sleeve (C) from front lines group. Discard all parts.
   Show/hide table

   Illustration 3	g06097596
   (F) 8L-5008 Pipe Elbow (G) 002-0639 Pipe Adapter (H) 389-4313 Clamp As (J) 192-5919 Clamp (K) 8T-4195 Bolt (L) 8T-4121 Hard Washer (M) 6V-7744 Locknut (N) 3B-6552 Pipe Elbow

2. Remove pipe elbow (F) and pipe adapter (G). Discard all parts.

3. Remove clamp assembly (H) and clamp (J) along with hardware, two bolts (K), four hard washers (L) and two locknuts (M). Discard all parts.

4. Remove two pipe elbows (N). Discard all parts.
   Show/hide table

   Illustration 4	g06097610
   (P) Grease port (R) 160-9496 Link

5. Remove two dog bone links (R) from machine to rework on grease ports (P), which accommodate banjo fittings. Save all parts.
   Show/hide table

   Illustration 5	g06105253
   (P) Grease port (S) 0.9 ± 0.2 x 45 degrees (T) 0.5 ± 0.2 x 45 degrees (U) 1.5 ± 0.5 x 45 degrees (V) Radius is 0.4 mm (0.02 inch) (X) 1 ± 0.4 x 45 degrees (Y) 7.5 mm (0.29 inch) (Z) 7.5 mm (0.29 inch) (AA) 15.0 mm (0.59 inch) (AB) 23.0 mm (0.91 inch)

6. Ground the grease port (P) of the link so that banjo's mating surface (P) will sit flat on the link's port as shown in Illustration 5.
   Show/hide table

   Illustration 6	g06105255
   (AC) 8T-3734 Weld Boss (AD) 9C-4935 Plate

7. Remove weld boss (AC) and plate (AD). Discard all parts.
   Show/hide table

   Illustration 7	g06105244
   (1) 294-4550 Weld Boss (W1) 6.0 mm (0.24 inch) all around fillet weld

8. Replace weld boss (AC) with weld boss (1). Finish weld boss (1) all around with a 6.0 mm (0.24 inch) fillet weld.
   Show/hide table

   Illustration 8	g06103463
   (R) 160-9496 Link (2) 452-7209 Special Bushing (3) 177-3484 Special Bolt As (4) 496-8217 Tube (5) 496-8218 Tube (6) 6J-3958 Pipe Coupling (7) 469-3265 Bracket As (8) 468-5523 Clamp (9) 8T-4196 Bolt (10) 8T-4121 Hard Washer

9. Install bracket assembly (7) and bracket assembly (8) per link with two bolts (9) and four washers (10).

   Install tube (4), tube (5), and adapter (6) on dog bone link (R) with two banjo fittings (2) and two banjo bolts (3).

   Repeat the same installation process for the second dog bone link (R).

   Show/hide table

   Illustration 9	g06098178
   (P) Grease port (R) 160-9496 Link

10. Install both dog bone links (R) by facing both front and rear ports in upward direction as shown in Illustration 9.
    Show/hide table

    Illustration 10	g06103466
    (9) 8T-4196 Bolt (10) 8T-4121 Hard Washer (11) 8T-4136 Bolt (12) 7X-7729 Washer (13) 496-8204 Bracket As (14) 496-8216 Hose As (15) 3B-8489 Grease Fitting (16) 177-3489 Coupling As (17) 8T-1887 Clip (18) 8T-1888 Clip (19) 353-7957 Grommet

11. Install two grease fittings (15) to bottom of bracket assembly (13). Use two adapters (16) to connect to the beka max grease system.

12. Use bolt (11) and washer (12) to secure bracket assembly (13).

13. Connect two hoses (14) to bracket assembly (13). Secure hose (14) to boss by using two clips (17), two clips (18) and grommets (19) with bolt (9) and washer (10).

14. Connect tube (4) and tube (5) to hose (14).

Rework procedure for 982M Wheel Loaders

Required Parts

Show/hide table

Illustration 11	g06098282
(1) 9R-2613 Weld Boss

Show/hide table

Illustration 12	g06105251
(A) 91.8 mm (3.61 inch) (B) 24.3 mm (0.96 inch) (C) 491.2 mm (19.34 inch) (D) 43.7 mm (1.72047 inch) (E) 210.8 mm (8.29 inch) (F) New location of 9R-2613 Weld Boss (W1) 6.0 mm (0.24 inch) all around fillet weld

1. Relocate boss (1) as per the dimension shown in Illustration 12.
   Show/hide table

   Illustration 13	g06098649
   (1) 9R-2613 Weld Boss (G) Hose clip

2. Flip hose clips (G) to accommodate boss (1).
   Show/hide table

   Illustration 14	g06098624
   (2) 452-7209 Special Bushing (3) 177-3484 Special Bolt As (4) 496-8208 Tube (5) 496-8209 Tube (6) 496-8206 Bracket As (7) 8T-4196 Bolt (8) 8T-4121 Hard Washer (9) 6V-7744 Locknut (10) 251-2139 Bracket (11) 8T-4200 Bolt (12) 8T-4224 Hard Washer (H) Dog bone link

   Show/hide table

   Illustration 15	g06103387
   (2) 452-7209 Special Bushing (3) 177-3484 Special Bolt As (5) 496-8209 Tube (6) 496-8206 Bracket As

3. Install two bracket assemblies (6) per link with two bolts (7), four washers (8), and two locknuts (9).

   Connect tube (4) and tube (5) to dog bone link (H) using banjo fitting (2) and banjo bolt (3) per tube.

   Secure tube (4) and tube (5) with clamp brackets using three tube clamps (10) and secure with three bolts (11) and washers (12) as shown in Illustration 14 and Illustration 15.

   Show/hide table

   Illustration 16	g06103382
   (8) 8T-4121 Hard Washer (13) 8T-4137 Bolt (14) 496-8204 Bracket As (15) 496-8203 Hose As (16) 8T-1887 Clip (17) 8T-1888 Clip (18) 353-7957 Grommet (19) 8T-4195 Bolt (20) 6J-3958 Pipe Coupling (J) Clipping point

4. On each lever, install bracket assembly (14) onto cross member and secure with bolt (13) and washer (8).

5. Attach two hose assembly (15) to bracket assembly (14). Clip hoses to the lever using two clips (16), two clips (17) and two grommets (18). Secure with two bolts (19) and two washers (8) per each hose.

6. Connect hose assembly (15) to tubes using pipe coupling (20) per connection.

7. Tape on hoses should be at the clipping point (J).