PRODUCT IMPROVEMENT PROGRAM FOR LINKAGE PIN CONVERSION TO GREASE (DAILY LUBRICATION) ON CERTAIN 992G WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR LINKAGE PIN CONVERSION TO GREASE (DAILY LUBRICATION) ON CERTAIN 992G WHEEL LOADERS

Usage:

SEBE7853-03

December 8, 2001
(Revised May 2002)
U-335
A-233
AU-225
S-175
H-132
O-256

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR LINKAGE PIN CONVERSION TO GREASE (DAILY LUBRICATION) ON CERTAIN 992G WHEEL LOADERS
6118		PI30110

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30110" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30110" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the December 8, 2001 (Revised January 2002)Service Letter. Changes have been made to the Service Claims Allowance.

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COMPLETION DATE	TERMINATION DATE
June 30, 2002	December 31, 2002

PROBLEM

The linkage pin lubrication system needs to be converted to grease on certain 992G Wheel Loaders. The linkage MFL pins may experience multiple failure modes causing loss of lubrication resulting in pin failure. The pin joints have been redesigned for grease lubrication to provide improved pin system reliability. When performing this service letter, please review PS40808. PS40808 supports installation of an autolube system.

AFFECTED PRODUCT

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Model	Identification Number
*** Group 1 ***
992G	7HR1-Up ADZ1-213
*** Group 2 ***
992G	ADZ214-338

PARTS NEEDED

6 - 1K6853 Fitting

6 - 1J9671 O-Ring

4 - 3B8489 Fitting

12 - 3J1907 O-Ring

5 - 3K0360 O-Ring

4 - 3Y2888 Connector

2 - 5B0935 Fitting

2 - 5K9239 Connector

3 - 5K9242 Union

2 - 5K9243 Elbow

6 - 5P4487 Adapter

2 - 5P5461 Nut

2 - 5P5463 Adapter

1 - 7M8485 O-Ring

15 - 8M2772 Clip ? Loop

12 - 8T4121 Washer - Hard

12 - 8T4133 Nut

2 - 8T4219 Stud ? Weld

1 - 9S4181 Plug

1 - 9S4185 Plug

6 - 9S4191 Plug

4 - 9S8005 Plug

1 - 9U0900 Plate

2 - 1062105 Elbow

10 - 1102023 Stud - Weld

1 - 2043573 Plate Assembly

5 - 2043582 Plate Assembly

1 - 2070698 Tube Assembly

1 - 2070699 Tube Assembly

1 - 2070700 Tube Assembly

1 - 2070701 Tube Assembly

1 - 2070702 Tube Assembly

1 - SEBU7009-04 992G Operation and Maintenance Manual

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 1 ***
100%	30	0	0	0	0
NOTE: This is a 30-hour job.
*** Group 2 ***
100%	18	0	0	0	0
NOTE: This is a 18-hour job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - The Linkage Pin Lubrication System Needs To Be Converted To Grease

MODELS INVOLVED - 992G Wheel Loaders

Dear Caterpillar Product Owner:

The linkage pin lubrication system needs to be converted to grease on certain 992G Wheel Loaders. The linkage MFL pins may experience multiple failure modes causing loss of lubrication resulting in pin failure. The pin joints have been redesigned for grease lubrication to provide improved pin system reliability. The grease conversion needs to be completed on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated December 8, 2001 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)
Attached to December 8, 2001 Service Letter

Rework Procedure

NOTE: Read and understand this entire procedure prior to starting with step 1.

NOTE: This procedure assumes that the C-Pin and E-Pin are lubricated with grease (see PI3262). The pin locations are shown in Table 1.

1. Weld two 8T4219 Studs to the right side of the left frame plate, inside the hitch area. Both studs should be approximately 127 mm toward the rear of the machine from the vertical rear plate of the front frame. The bottom stud will be approximately 470 mm above the bottom hitch plate and the top stud will be approximately 545 mm above the bottom hitch plate. These 8T4219 Studs are labeled AG in Image 1. See Image 1. NOTE: The 8T4219 Studs have a ceramic arc shield. If a spot welder is not used, break the shield off prior to welding. If a spot welder is used, break the shield off after welding.

NOTE: The dimensions given in steps 1-7 exactly match the dimensions in the Images for easier correlation between the text and the Image. The stud locations are +/- 5 mm in all directions.

2. Weld two 110023 Studs to the right side of the left frame plate, inside the hitch area. Both studs should be approximately 70.5 mm toward the rear of the machine from the vertical rear plate of the front frame. The bottom stud will be approximately 873.7 mm above the bottom hitch plate and the top stud will be approximately 1447.7 mm above the bottom hitch plate. These 1102023 Studs are labeled AH in Image 1. NOTE: The 1102023 Studs have a ceramic arc shield. If a spot welder is not used, break the shield off prior to welding. If a spot welder is use, break the shield off after welding.

3. Weld one 1102023 Stud to the bottom of the top hitch plate, inside the hitch area. The stud should be approximately 342 mm to the left of the center of the frame (68 mm from the left frame plate) and approximately 399 mm toward the front of the machine from the top hitch pin center (318 mm behind the vertical rear frame plate). See Image 2. NOTE: Image 2 is looking up at the bottom of the top hitch plate on the front frame. The stud is welded on the left side of the machine in front of the hitch.

4. Weld two 1102023 Studs on the top of the top hitch plate. Both studs should be approximately 342.5 mm to the left of the center of the frame (68 mm from the left frame plate). The rear most stud should be approximately 515.4 mm toward the front of the machine from the top hitch pin center (271 mm from the back of the G-Pin Tower). The front stud should be approximately 708.8 mm toward the front of the machine from the top hitch pin center (77 mm from the back of the G-Pin Tower). See Image 3.

5. Weld two 1102023 Studs to the left side of the left frame plate, above and behind the fender mount area. The front most stud will be approximately 421.5 mm above the top of the hydraulics cutout in the frame, and approximately 70.6 mm toward the rear of the machine from the vertical front of the hydraulics cutout in the frame. The rear stud will be approximately 383.7 mm above the top of the hydraulics cutout in the frame, and approximately 529.4 mm toward the rear of the machine from the vertical front of the hydraulics cutout in the frame. These 1102023 Studs are labeled AJ in Image 4. See Image 4.

6. Weld two 1102023 Studs to the back of the G-Pin tower. Both studs should be approximately 47 mm to the right of the left edge of the plate. The top stud should be approximately 484 mm below the top edge of the plate, and the bottom stud should be approximately 922 mm below the top edge of the plate. See Image 5.

7. Weld one 1102023 Stud to the left side of left plate of the G-Pin tower, below and behind the G-Pin bore. The stud will be approximately 163.4 mm toward the rear of the machine, and 126 mm below the center of the G-Pin. See Image 6.

NOTE: On Group 2 machines (ADZ214-ADZ338), or any machine previously converted to static grease linkage joints, skip to step 11.

Drain all Oil from linkage joints A, B, F, and K by removing the 3K8460 Plugs with 1J9671 O-Rings from both ends, and the 9S8005 Plug with 3K0360 O-Ring from the top and/or bottom port/s of each joint. The pin locations are shown in Table 1.
Drain all Oil from the G pin joint by removing the 3K8460 Plugs with 1J9671 O-Rings from both ends, and the 9S4185 Plug with 3K0360 O-Ring from the port in the tilt cylinder. The pin locations are shown in Table 1.

10. Drain all Oil from Y-Pin joint by removing the 3K8460 Plugs with 1J9671 O-Rings from both ends, and the 9S4181 Plugs with 7M8485 O-Ring from the fill and drain ports in the Y-Pin casting in the front frame. The pin locations are shown in Table 1.

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Table 1 - Pin Location
A-Pin	Boom to Front Frame Joint
B-Pin	Boom to Bucket Joint
C-Pin	Bucket Link to Bucket Joint
E-Pin	Rod End of Tilt Cylinder to Bucket Link and Boom Link Joint
F-Pin	Boom to Boom Link Joint
G-Pin	Head End of Tilt Cylinder to Front Frame Joint
K-Pin	Rod End of Lift Cylinder to Boom Joint
Y-Pin	Head End of Lift Cylinder to Front Frame Joint

11. Replace the 1455007 Plate Assembly on the left side of the A-Pin with a 2043582 Plate Assembly by removing the 1472001 Bolt, 9X8259 Washer and 1472383 Spacer. Check reusability of the 1439740 Seal Assembly and the 6V5103 O-Ring. If reusability of either is in question, the seal should be replaced. Align dowels in plate assembly with dowel holes in pin such that a fill port is located in the lower quadrant of pin. The 1472001 Bolt should be tightened to a torque of 2700 +/- 300 N.m (2000 +/- 220 lb. ft).

12. Repeat Step 11 for each the B, Y, and K-Pins. Repeat step 11 for the F-Pin noting the 1455007 Plate Assembly is on the right side of the F-Pin and the 2043582 Plate Assembly will be installed on the right side of the joint. The pin locations are shown in Table 1.

13. Replace the 1329898 Plate Assembly on the left side of the G-Pin with a 2043573 Plate Assembly by removing the 7X2583 Bolt, and 9X8258 Washer. Check reusability of the 1R1056 Seal Assembly and the 6V5052 O-Ring. If reusability of either is in question, the seal should be replaced. Align dowels in plate assembly with dowel holes in pin such that a fill port is located in the lower quadrant of pin. The 7X2583 Bolt should be tightened to 1600 +/- 200 N.m (1180 +/- 150 lb. ft).

NOTE: This procedure assumes the boom has vented 1531853, 1531854 and 1531855 spacers between the bearings. If the spacers are not vented (recently replaced boom, or spacers), proceed to step 24.

NOTE: On Group 2 machines (ADZ214-ADZ338), or any machine previously converted to static grease linkage joints, perform a 250 hour maintenance grease purge and skip to step 23.

14. Replace the 9S8005 Plug and 3K0360 O-Ring in the bottom port of the A-Pin joint. Use a ½" OD or smaller tube to completely fill the joint with grease through the top port. Refer to Table 4 for the correct grease. Connect the tooling listed in Table 2 to the top port. NOTE: The small tube will allow air displaced by the incoming grease to escape as the joint fills.

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Table 2 - Recommended Tooling - Joint Port Connections
A, B, F, G and K Joints
Part Number	Part Name	Description
9T6635	Plug	3/4-16 to 1/8-27 nptf (female)
3K0360	O-Ring
3B8489	Fitting	1/8-27 nptf (male) to grease zerk
Y Pin Joint
Part Number	Part Name	Description
3T0811	Adapter	5/16-12 to 1/4-18 nptf (female)
7M8485	O-Ring
3B8490	Fitting	1/4-18 nptf (male) to grease zerk

15. Repeat step 14 for each the B, and K-Pins.

16. If the machine has an extended boom go to step 17. If the machine has a standard boom, use a ½" OD or smaller tube to completely fill the F-Pin joint with grease through the port in the top of the boom. Connect the tooling listed in Table 2 to the port in the top of the boom. Skip to step 18.

17. Use a ½" OD or smaller tube to get as much grease as possible into the F-Pin joint through the port in the bottom of the boom. Connect the tooling listed in Table 2 to retain the grease.

18. Use a ½" OD or smaller tube to completely fill the G-Pin joint with grease through the port in the tilt cylinder. Connect the tooling listed in Table 2 to the port in the tilt cylinder.

19. Replace the 9S4181 Plug and 7M8485 O-Ring in the bottom port of the Y-Pin casting in the front frame. Use a ½" OD or smaller tube to completely fill the joint with grease through the top port of the Y-Pin casting in the front frame. Connect the tooling listed in Table 2 to the top port.

20. With the Plugs still removed from the ports in the ends of the pin, (flag and end plate) (see steps 8-10), pump grease into the A-Pin through the tooling previously installed as listed in Table 2 (see steps 14-19). Continue to add grease until a steady flow of grease (without air bubbles) comes out of the ports at each end of the joint.

NOTE: If grease only comes out one side, 3K8460 Plugs with 1J9671 O-Rings (Right/Flag end of joint), or 9S4191 Plugs with 3J1907 O-Rings (Left/New End Plate end of joint) may have to be used in order to block the flowing end and force grease out of the opposite end. 21. Collect and dispose of the old grease appropriately.

22. Repeat Step 20 and 21 for each the B, F, G, K and Y-pin joints.

NOTE: The previous procedure pressurizes the joint. If the joint has trapped air, the air will be compressed during the procedure resulting in residual pressure in the joint. Extreme caution should be used in step 23 to slowly release the residual pressure. 23. The previous procedure pressurizes the joint. If the joint has trapped air, the air will be compressed during the procedure resulting in residual pressure in the joint. Using extreme caution to slowly release the residual pressure, replace the tooling previously installed as listed in Table 2 (see steps 14-19) with the Plugs and O-Rings listed in Table 3.

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Table 3 - Fill Port Plugs
A, B, F and K-Pin Joints
Part Number	Part Name
9S8005	Plug
3K0360	O-Ring
G-Pin Joint
Part Number	Part Name
9S4185	Plug
3K0360	O-Ring
Y-Pin Joint
Part Number	Part Name
9S4181	Plug
7M8485	O-Ring

24. Install one 5K9243 Elbow in each of the two 5P5463 Adapters and tighten. Install two Adapter and Elbow assemblies into the two closely spaced holes in the 9U0900 Plate using one 5P5461 Nut on each adapter. Tighten both 5P5461 Nuts with connection port of the 5K9243 Elbows directed straight across the plate between the wider spaced holes. Install and tighten two 5B0935 Fittings into the 5P5463 Adapters. Mount the Plate assembly to the two weld studs installed in Step 1 using two 8T4133 Nuts and two 8T4121 Washers with the 5B0935 Fittings pointing to the left. See Image 7.

25. Install tubes 2070699 and 2070702. The single bend end of the 2070699 Tube connects to the top elbow on the plate assembly installed in step 24, passes the studs installed in step 2, passes to the left side of the stud installed in step 3, and wraps around the top hitch plate. The shorter bend end of the 2070702 Tube connects to the bottom elbow on the plate assembly installed in step 24, passes the studs installed in step 2, and terminates near the stud installed in step 3. Fasten both tubes to each of the studs installed in step 2 using a 8T4133 Nut, a 8T4121 Washer and two 8M2772 Clips at each stud. See Image 8 and Image 9 (2070699 Tube is 28, and 2070702 is 33). NOTE: The 2070699 Tube goes behind the studs, and the 2070702 Tube goes in front of the studs.

26. Install one 5K9242 Union in the end of each the 2070699 and 2070702 Tubes.

27. Install 5K9239 Connector into 1062105 Elbow and tighten. Install the elbow and connector assembly in the lowest port in the plate on the left end of the A-Pin joint with a 3J1907 O-Ring. Do not tighten elbow. Install 9S4191 Plug with 3J1907 O-Ring in remaining port in plate on left end of the A-Pin.

28. Repeat step 27 for the G-Pin.

29. Connect the "U-Bend" end of the 2070701 Tube to the union installed in the 2070702 Tube in step 26. The 2070701 Tube passes the stud installed in step 3, wraps around the top hitch plate, passes the two studs installed in step 4, and proceeds up the back of the G-Pin tower passing the bottom stud installed in step 6. See Image 10

30. Connect the "straightest" end of the 2070698 Tube to the union installed in the 2070699 Tube in step 26. The 2070698 Tube passes the studs installed in step 4, passes to the outside of the left frame plate, passes above the rear stud installed in step 5 and below the front stud installed in step 5 to connect to the connector installed at the A-Pin in step 27. Do not connect tube at A-Pin yet. See Image 11. Tighten both ends of 2070699 Tube, and the union end of 2070698 Tube. Add grease at the top 5B0935 Fitting installed in step 24 to fill both tubes. Connect and tighten the 2070698 Tube at the A-Pin, and tighten the elbow installed in step 27.

31. Fasten the 2070699 and 2070701 Tubes to the stud installed in step 3 using an 8T4133 Nut, an 8T4121 Washer and two 8M2772 Clips. See Image 8. NOTE: The 2070699 Tube goes on the left side of the stud, and the 2070701 Tube goes on the right side of the stud. 32. Fasten the 2070698 and 2070701 Tubes to the two studs installed in step 4 using an 8T4133 Nut, an 8T4121 Washer and two 8M2772 Clips at each stud. See Image 8 and Image 12. NOTE: The 2070698 Tube goes on the left side of the studs, and the 2070701 Tube goes on the right side of the studs.

33. Fasten the 2070698 Tube to the two studs installed in step 5 using 8T4133 Nut, 8T4121 Washer, and 8M2772 Clip at each stud. Fasten the 2070701 Tube to the bottom stud installed in step 6 using 8T4133 Nut, 8T4121 Washer, and 8M2772 Clip.

34. Install 5K9242 Union at open end of 2070701 Tube.

35. Connect the "straightest" end of 2070700 Tube to the union installed in step 34. The 2070700 Tube passes to the left of the top stud installed in step 6, passes to the outside of the G-Pin tower, and passes below the stud installed in step 7 to connect to the connector installed at the G-Pin in step 28. Do not connect tube at G-Pin yet. Tighten both ends of each the 2070701, 2070702 Tubes, and the union end of 2070700 Tube. Add grease at the bottom 5B0935 Fitting installed in step 24 to fill the three tubes. Connect and tighten the 2070700 Tube at the G-Pin, and tighten the elbow installed in step 28. Fasten the 2070700 Tube to the top stud installed in step 6 and the stud installed in step 7 using 8T4133 Nut, 8T4121 Washer, and 8M2772 Clip at each stud.

36. Install 3B8489 Fitting into 3Y2888 Connector. Install the fitting and connector assembly with 3J1907 O-Ring into the lowest port of the 204-3582 Plate installed on the left side of the B-Pin in steps 11. Install 9S4191 Plug with 3J1907 O-Ring into the remaining port in the 204-3583 Plate at the B-Pin.

37. Install 1K6853 Fitting into 5P4487 Adapter. Install the fitting and connector assembly with 1J9671 O-Ring to the highest port on the right side of the B-Pin joint where the 3K8460 Plug was removed in Step 8. Replace the 3K8460 Plugs with 1J9671 O-Ring that was removed in step 8 in the remaining port on the right side of the joint.

38. Repeat steps 36 and 37 at the F, K, and Y-Pin joints.

39. Repeat step 37 at the A and G-Pin joints.

40. Add grease at the 3B8489 Fittings installed at each the B, F, K and Y-Pin joints, and the two 5B0935 Fittings at the remote A and G-Pin joint lube points. Continue to add grease at each joint until a steady flow of grease (without air bubbles) comes out of the 1K6853 Fittings on the right end of each joint.

NOTE: Make sure the joint seals are functioning properly to direct grease to the opposite end of the joint. If grease escapes at any of the sealing points in the joint, the right side bearing will not be adequately lubricated, and will fail. Any failed seal must be repaired.

Note: Pin joints should be lubricated daily or after every 10 hours of operation. Refer to Table 4 for the correct grease.

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Grease Recommendations (Table 4)
Grease/NLGI Grade	Ambient Temperature Range	Part Numbers
Auto-Lube/1	-20 to 90 Deg. F -30 to 32 Deg. C	1619203 Cartridge
		1833432 5 gal. Plastic
		1610970 16 gal. Keg
		1610971 55 gal. Drum
		1608028 Bulk/lb.
		1855339 35 lb. Pail-EAME
		1855340 120 lb. Keg-EAME
		1855341 400 lb. Drum-EAME
Low Ambient Arctic Platinum/000	-74 to 40 Deg. F -60 to 5 Deg. C	1316532 5 gal. Plastic
		1316531 5 gal. Metal
		1316533 16 gal. Keg
		1316534 55 gal. Drum
		1316536 3500 lb. Tote
High Ambient Desert Gold/2	20 to 150 Deg. F -5 to 65 Deg. C	1291938 Cartridge
		1291939 1lb. Can
		1291941 5 gal. Plastic
		1291942 5 gal. Metal
		1291943 16 gal. Keg
		1291944 55 gal. Drum
		1291946 3500 lb. Tote