Armado 994d Inglés

994D WHEEL LOADER 3TZ00001-00336 (MACHINE) POWERED BY 3516B E...
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Producto: WHEEL LOADER

Modelo: 994D WHEEL LOADER 3TZ
Configuración: 994D WHEEL LOADER 3TZ00001-00336 (MACHINE)
POWERED BY 3516B Engine
Instrucción Especial
994D Wheel Loader Assembly Procedure{7000}
Número de medio -REHS0351-04 Fecha de publicación -01/03/2004 Fecha de actualización -11/03/2004
i02068720
994D Wheel Loader Assembly Procedure{7000}

SMCS - 7000
Wheel Loader:
994D (S/N: 3TZ1-UP)
Introduction
This Special Instruction contains the assembly procedure and the installation information that is
required to assemble the 994D Wheel Loader when the machine is shipped to the field.
Personal injury or death can result from improper assembly

procedures.
Do not attempt any assembly until you have read and understand the
assembly instructions.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
https://127.0.0.1:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 16/12/2006
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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
Keep the oil in the hydraulic system at the correct level in order to prevent pump cavitation.
Clean all of the surfaces before you install any parts.
Reference: Parts Manual, SEBP2793; Operation and Maintenance Manual, SEBU7145; Service
Manual, RENR2500
Do not perform any procedure that is outlined in this publication or do not order parts until you
understand the information that is contained in this document.
Illustration 1 g00760975
Prepare the Site

Choose a flat, well drained area for assembly. The area should be approximately 24 m (78 ft) long
and 24 m (78 ft) wide. Place the rear axle in the center of the area. Leave the axle on the shipping
supports until the axle is installed on the chassis.
Remove the shipping supports from the chassis and place the chassis in position over the rear axle.
As the rest of the components are unloaded, place the components near the chassis.
Leave space in order to allow movement of the cranes. Place the large wooden boxes out of the way.
Open the boxes in order to become familiar with the contents. Do not open the bags of hardware.
The bags of hardware are marked for easy identification and for orderly use.
Identify the Parts and Organize the Parts
Organize the parts that are shipped with the machine according to the following table. This will
reduce the number of lost parts and this will reduce the amount of time that is lost in searching for
parts.
Table 1
Next Level Part

Next Level Part Name Location in Assembly Procedure
Number
Hand Rail on the Rear Fender
Fuel Tank
Bumper
Hand Rail on the Rear Platform
7I-5484 Handhold Fastener
Hand Rail on the Front Platform
Hand Rail on the Hood
Exhaust Extensions
7I-5909 Brake Line Shield Group Guard on the Front Brake Lines
7X-0721 Plates and Films Exhaust Extension
8X-0026 Transmission Guard Group Guard for the Transmission
8X-0029 Articulated Hitch Procedure for Pinning
8X-0032 Kickout and Positioner Lift Kickout
8X-0041 Grease Lines Group Rear Axle
8X-0043 Steering Frame Lock Procedure for Pinning
Installation of Outrigger
8X-0625 Platform Mounting Group
Installation of Cab
Rims
8X-1316 Rim Mounting Group
Tires
Drawbar And Bumper Fastener Fuel Tank
8X-1379
Group Bumper
8X-1398 Tilt Cylinder Lines Group Tilt Cylinders
8X-1399 Tilt Cylinder Lines Group Tilt Cylinders
8X-1536 Kickout and Positioner Tilt Kickout
8X-1717 Axle Oil Cooler Lines Group Front Axle
8X-1721 Service Brake Lines Group Front Axle
Bottom Guard Fastener Group
8X-1736 Guard for the Transmission
8X-1740 Fixed Axle Fastener Group Front Axle

Oscillating Axle Fastener
8X-1741 Rear Axle
Group
Lines for the Tilt Cylinder
8X-1745 Grease Lines Group
Lift Arms
Installation of Outrigger
8X-1747 Platform Mounting Group Installation of Platform
Support Plates for the Platform
Front Fender
101-2658 Fender Fastener Group
Rear Fender
Fuel Tank
101-3756 Fuel Tank Fitting
Bumper
101-7345 Walkway Rear Fender
Front Axle
104-4751 Drive Shaft
Procedure for Pinning
105-3235 Drive Shaft Joint Assembly
107-0256 Mirror Mirror
107-0257 Mirror Mirror
Bumper
113-0672 Step Group
Fuel Tank
114-2820 Tilt Cylinder Gp Tilt Cylinder
114-2821 Tilt Cylinder Gp Tilt Cylinder
Tilt Cylinder
121-9293 Linkage Pin and Seal
Lift Arms
Fast Fill Automatic Lubrication
180-1510 Rear Axle
Service
Precleaner
129-0580 Fumes Disposal Group
Dust Ejector
Precleaner
129-0581 Dust Ejector Group
Dust Ejector
129-0610 Stop Lighting Group Brake Light
Precleaner
132-9371 Air Cleaner Gp
Dust Ejector
Precleaner
129-0685 Air Lines
Dust Ejector
Filter Change Indicator Group Precleaner
133-6503
Dust Ejector
Precleaner
133-6613 Precleaner Group
Dust Ejector
135-3879 Exhaust Extension Exhaust Extensions
Transmission Control Wiring
152-8934 Procedure for Pinning
Group
Hand Rail on the Rear Fender

Fuel Tank
153-7968 Handhold Bumper
Hand Rail on the Rear Platform
Hand Rail on the Front Platform
Hand Rail on the Hood
Exhaust Extensions
Steering Neutralizer Valve and Cab
154-8015
Mounting Procedure for Pinning
156-6350 Automatic Lubrication Gp Procedure for Pinning
Position Sensor for the VIMS Loader
157-3723 Front Wiring
Payload System
158-8024 Flood Lighting Gp Front Fender
160-4337 Flood Lighting Gp Lighting on the Platform
160-4340 Cab and ROPS Lighting Gp Lighting on the ROPS
Platform Assembly
162-2984 Operator Platform
Door on the Platform
165-4012 ROPS Fastener Group ROPS
Dimensions and Weights of Components

The shipping configuration of the 994D Wheel Loader is dependent on the destination of the
machine and on the transportation that is available. In some instances, the Engine End Frame and the
Non-Engine End Frame are shipped separately.
The following table contains the approximate weight of machine components in various shipping
configurations.
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly.
Approximate weight of the assembly is given below.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
Table 2
Dimensions And Weights

Component Net Weight Length Width Height
Non-Engine End Frame
20827 kg 1422 mm (56 2667 mm (105 3810 mm (150
(45915 lb) inch) inch) inch)
Engine End Frame
36189 kg 7925 mm (312 2616 mm (103 3810 mm (150
Complete Chassis (1)
64695 kg 11278 mm (444 2895 mm (114 4013 mm (158
Complete Chassis (2)
76004 kg 11278 mm (444 2895 mm (114 4013 mm (158
Lift Arms (Standard)
19928 kg 6325 mm (249 2362 mm (93 1905 mm (75
Lift Arms (High Lift)
22431 kg 7061 mm (278 2387 mm (94 2337 mm (92
Front Axle with Rims
21374 kg 2057 mm (81 5436 mm (214 1930 mm (76
Rear Axle with Rims
22273 kg 2057 mm (81 5436 mm (214 1930 mm (76
Rock Bucket (3)
20518 kg 3505 mm (138 5639 mm (222 2997 mm (118
Bumper and Fuel Tank
5929 kg (13071 2438 mm (96 4927 mm (194 1066 mm (42
lb) inch) inch) inch)
Left Hand Platform
1271 kg (2802 2489 mm (98 3403 mm (134 1270 mm (50
Right Hand Platform
1298 kg (2861 2565 mm (101 3403 mm (134 1270 mm (50
Cab
1216 kg (2680 1524 mm (60 1879 mm (74 2463 mm (97
Tire (49.5 x 57)

3939 kg (8683 3581 mm (141 1279 mm (50 3581 mm (141
Tire (53.5/85 x 57)
5448 kg (12010 3912 mm (154 1397 mm (55 3912 mm (154
Rim 1755 kg (3869 1753 mm (69 1219 mm (48 1753 mm (69

Tire and Rim (49.5 x 57)
5694 kg (12553 3581 mm (141 1295 mm (51 3581 mm (141
Tire and Rim (53.5/85 x
57) 7200 kg (15873 3912 mm (154 1397 mm (55 3912 mm (154
ROPS and Parts Kit
6065 kg (13371 2235 mm (88 2057 mm (81 2616 mm (103
Front Fender and Rear
Fender 1326 kg (2923 3835 mm (151 2337 mm (92 1702 mm (67
Hand Rails
772 kg (1701 lb) 3658 mm (144 2337 mm (92 1473 mm (58
inch) inch) inch)
Exhaust Stack and
Mounting Pins 1943 kg (4283 3150 mm (124 1295 mm (51 864 mm (34
Tilt Cylinders
1862 kg (4105 2896 mm (114 1219 mm (48 737 mm (29
Tilt Links
1099 kg (2422 2413 mm (95 813 mm (32 457 mm (18
(1) Non-Engine End Frame and Engine End Frame
(2) Non-Engine End Frame, Engine End Frame, and Shipping Supports
(3) Capacity of 17.6 m3 (23 yd3)
Torque Specifications
This is a test.
Requirements for the Crane

The 994D Wheel Loader is shipped in several sections. The heaviest section is the front frame and
the rear frame. The front frame and the rear frame weigh approximately 76000 kg (167500 lb). Two
cranes will be required in order to unload this shipping module.
The capacity of the cranes and the reach of the cranes must be considered because of the width and
the height of the Wheel Loader. A spreader bar must be used to lift the rear chassis in order to
prevent damage to the hood.
After the machine is unloaded the larger crane will not be required unless the front frame and the
rear frame are assembled simultaneously.
Table 3
Lifting Dimensions
Description Dimension
Centerline to side of Engine End Frame

1321 mm (52 inch)
Centerline to side of Non-Engine End Frame

1346 mm (53 inch)
Centerline to the edge of the axle without the tires

2489 mm (98 inch)
Ground level to the top of the ROPS

6553 mm (258 inch)
Length of the machine with high lift arm assembly and rock bucket
17424 mm (686 inch)
Width of the machine and the bucket

5664 mm (223 inch)
Ground level to the top of the hood on the Engine End Frame (1)
4572 mm (180 inch)
Ground level to the top of the Non-Engine End Frame (2)

4343 mm (171 inch)
Lifting eye to the top of the hood on the Engine End Frame
2743 mm (108 inch)
Minimum spreader bar width

2743 mm (108 inch)
(1) The machine should be supported on 1219 mm (48 inch) blocks.
(2) The machine should be supported on533 mm (21 inch) blocks.
Equipment for Assembly

The following equipment will be required in order to assemble the 994D Wheel Loader.
z Two cranes with an individual capacity of 68100 kg (150135 lb)
z A lift truck with a capacity of 6810 kg (15000 lb)
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z Nitrogen Charging Equipment
z One portable air compressor with a capacity of 3 m3 (100 ft3) per minute
z Lifting equipment for personnel with a weight capacity of 227 kg (500 lb) and a height of 6.1
m (20 ft)
z 110 Volt Generator
z One 1.8 m (6 ft) ladder and one 2.4 m (8 ft) ladder
z Blocking for the Engine End Frame
z Blocking for the Non-Engine End Frame
z Guide Bolts
z 5P-0306 Vacuum Transducer
z 5P-3415 Adapter
z 3D-2824 O-Ring Seal
z Paint Remover or Cleaning Solvent
z Lifting Beams, Lifting Slings, Chains, Cables, Shackles and Hooks.
Note: If the Engine End Frame and the Non-Engine End Frame are attached the blocking for the
engine end frame should be approximately 914 mm (36 inch)deep, 1828 mm (72 inch) wide, and
1727 mm (68 inch) tall. The blocking will create clearance for the largest tires and for the largest
rims on the 994D Wheel Loader. The height of the blocking should be reduced by 305 mm (12 inch)
if the machine is equipped with smaller tires or smaller rims.
Note: If the Engine End Frame and the Non-Engine End Frame are attached the blocking for the
non-engine end frame should be approximately 914 mm (36 inch)deep, 1828 mm (72 inch) wide,
and 1219 mm (48 inch) tall. The blocking will create clearance for the largest tires and for the largest
rims on the 994D Wheel Loader. The height of the blocking should be reduced by 305 mm (12 inch)
if the machine is equipped with smaller tires or smaller rims.
Tooling for Assembly

The majority of the fasteners on the 994D Wheel Loader are metric. Some components on the
machine may use standard fasteners. An example of these components may be the engine or the
transmission. Machine components will have a single type of fastener.
Hand Tools that are Required for Assembly
z 1U-7820 Wrench Set
z 8T-5183 Drive Extension
z The following sockets will be required for assembly.
Table 4
Thread Size (mm) Socket Size (mm) Part Number Description

8 × 1.25 13 1U-7927 6 Point, 1/2 Inch Drive
16 × 2.00 24 6V-9117 6 Point, 3/4 Inch Drive
20 × 2.5 20 152-1058 12 Point, 3/4 Inch Drive
24 × 3.0 36 4C-6723 6 Point, 1 Inch Drive
30 × 3.5 46 4C-9812 (1) No. 5 Spline Drive
36 × 4.0 55 8H-8544 12 Point, 3/4 Inch Drive
(1) Used for installation of the tires
z The following adapters for the sockets will be required for assembly.
Table 5
Part Number Description

4C-9813 1 Inch Female to No. 5 Spline Drive (1)
2P-8261 3/4 Inch Female to 1 Inch Male
8H-8561 1/2 Inch Female to 3/4 Inch Male
(1) Used for installation of the tires and installation of the rims
Tooling that is Required for Setting Torque
z 6V-7820 Torque Multiplier Gp Capacity of 1630 N·m (1200 lb ft)
z 6V-6080 Torque Multiplier Gp Capacity of 4335 N·m (3200 lb ft)
z 9U-7465 Wrench
z 8T-5230 Torque Wrench
z 4C-9814 Reaction Bar
z 6V-3146 Extension
z 6V-4170 Adapter
z Special Instruction, SEHS7150
z A 1.8 m (6 ft) length of pipe which has an inside diameter that fits the handle of a torque
multiplier
z The following torque wrench adapters will be required for assembly.
Table 6
Socket Size (mm) Part Number

20 4C-6194 (1)
24 4C-9563 (2)
30 4C-9564 (3)
36 4C-9565 (4)
(1) Used for installation of the drive shafts
(2) Used for installation of the supports at the front of the cab
(3) Used for installation of the mounts on the rear fender
(4) Used for installation of the resilient mounts at the rear of the cab
Guide Bolts that are Required for Assembly
The following guide bolts should be fabricated from metric bolts. Remove the head of the bolt.
Table 7
Diameter (mm) Part Number Length
20 8T-6381 (1)
120 mm (4.7 inch)
24 6V-8198 (1)
200 mm (7.9 inch)
30 8T-6624 (2)
180 mm (7.1 inch)
36 3E-7441 (3)
440 mm (17.3 inch)
(1) Used for assembly of the non-engine end frame and the engine end frame
(2) Used for assembly of the bumper and the fuel tank
(3) Used for assembly of the oscillating axle
Jacks that are Required for Assembly
Assembly of the non-engine end frame and the engine end frame will require several jacks. Each
jack should be able to support the combined weight of the non-engine end frame and the engine end
frame. The jacks should have a lifting capacity of 76 to 102 metric tons (75 to 100 tons).
z 80.8 metric ton (79.5 ton) jack stand gp
Reference: Lift Stand Brochure, NEPH5586; Lift Stand Tool Operating Manual, NEHS0603
Lift Eyes and Link Brackets that are Required for Assembly
z The following lifting brackets will be required for assembly.
Table 8
Part Number Size (mm) Capacity (1)
3E-3882 8
144 kg (317 lb)
4C-8358 10
248 kg (547 lb)
4C-8359 12
410 kg (904 lb)
3E-3879 16
610 kg (1345 lb)
3E-3880 20
990 kg (2183 lb)
3E-3881 24
1584 kg (3492 lb)
9U-5986 30
2475 kg (5456 lb)
9U-5887 48
7600 kg (16755 lb)
(1) Rated Capacity with a 0° Load
z The following link brackets will be required for assembly.
Table 9
Part Number Capacity Opening (mm)
138-7573
1022 kg (2250 lb) 10 mm (0.4 inch)
138-7575
1816 kg (4000 lb) 12 mm (0.5 inch)
138-7574
4086 kg (9000 lb) 20 mm (0.8 inch)
138-7576
4086 kg (9000 lb) 33 mm (1.3 inch)
Slings that are Required for Assembly
If a tire handler or a lift truck that is capable of handling tires is not available, two slings will be
required in order to mount the tires. The slings will also be required for installation of the following
items: lift arm pins, tilt cylinders, hand rails and fenders.
Table 10
Part Number Capacity of the

Type Width Length
Choker
Eye and Eye Type

1U-8256 50.8 mm (2.0 1.8 m (6.0 ft)
III 2252 kg (4965 lb)
inch)
Eye and Eye Type

1U-8260 76.2 mm (3.0 3.0 m (10.0 ft)
III 3378 kg (7447 lb)
inch)
Taps and Dies that are Required for Assembly
The following taps and dies will be required for assembly.
Table 11
Thread Size (mm) Tap Die

10 × 1.5 8T-3087 8T-3070
12 × 1.75 8T-3091 8T-3074
16 × 2.0 8T-3096 8T-3078
20 × 2.5 4C-4967 4C-4962
24 × 3.0 4C-4968 -
30 × 3.5 4C-4969 -
36 × 4.0 4C-4970 -
Maintenance Aids
z 9S-3263 Thread Lock Compound
z 4C-5593 Anti-Seize Compound
z 1U-8268 Dry Film Lubricant
z 4C-5599 Anti-Seize Compound
Cleaning
Clean all surfaces on parts before the parts are installed. Remove all burrs and all nicks from parts
before the parts are installed. Use 138-8440 Component Cleaner in order to clean mating surfaces.
Use 4C-4188 Paint and Decal Remover for the final cleaning of mating parts.
Equipment that is required for the Commissioning Procedure

The following items will be required when the machine is completed and prepared for the
commissioning procedure.
z JEBD3003 Electronic Technician Software CD and Getting Started Guide
z JERD2093 Cat Common Services
z JERD2124 Electronic Technician Program - Software Only
z JERD2129 Electronic Technician Engine/Machine Subscription
z JERD2137 VIMS Dealer License - Dealers Only
z JERD2138 VIMS Annual Subscription - Dealer
z NEXG4523 Communications Adapter SPM (v1.2)
z 7X-1425 Data Link Cable As
z 7X-1700 Communication Adapter Gp
z 127-9797 VIMS-PC Cable
z 139-4166 Data Link Cable As
Assembly Sequence
The following list is an overview of the assembly process for all of the major components of the
machine. The list is only a suggested sequence of assembly. The list only includes steps for assembly
of major machine components. Refer to the specific sections of this Special Instruction for detailed
assembly procedures.
1. Position the cranes, the blocking, and all of the major components except the non-engine end
frame and the engine end frame.
2. Position the non-engine end frame and the engine end frame on blocking over the rear axle.
3. If the two frames are not attached, pin the non-engine end frame to the engine end frame.
4. If the two frames are not attached, install the drive shafts between the non-engine end frame
and the engine end frame.
5. If the two frames are not attached, install the steering neutralizer valves and the steering
neutralizer lines.
6. If the two frames are not attached, connect the steering cylinders. Complete any remaining
connections between the engine end frame and the non-engine end frame.
7. Install the hand rails.
8. Install the rear axle and the front axle.
9. Install the drive shafts.
10. Install the rims and the tires.
11. Remove all of the supports from the chassis.
12. Install the rear bumper and the fuel tank.
13. Install the platform.
14. Install the front fender and the rear fender.
15. Install the cab.
16. Complete all connections between the cab and the frame.
17. Install the ROPS.
18. Install the attachments on the hood.
Note: Before the machine is started ensure that the following fluid reservoirs are full:
hydraulic, engine, pump drive and autolube
19. Start the engine.
20. Install the lift arms and the tilt linkage.
21. Install the tilt cylinders and the tilt cylinder lines.
22. Install the bucket.
23. Install the lighting and the mirrors.
24. Install the guards on the transmission.
25. Check all fluid reservoirs and fill all fluid reservoirs.
26. Complete the commissioning procedure for the machine.
Tips for the Assembly Process

1. Ensure that the appropriate lifting equipment is in place before the machine arrives on the
work site. The weight of the non-engine end frame and the engine end frame is 76004 kg
(167560 lb). Ensure that the following items are capable of supporting the machine weight:
chains, spreader bar, shackles, link brackets and lifting eyes. The weight of a complete
machine with a 21 cubic yard bucket and the largest tires that are available is 208350 kg
(459340 lb).
2. If two cranes are available on the work site, use two cranes in order to unload the machine.
Position the rear axle and the differential housing. Position the machine over the rear axle.
Place supports under the machine. The supports under the machine should be high enough that
the assembly process can be completed without repositioning the chassis.
3. A crew of five persons will be required in order to assemble the machine. The assembly
process will require four persons and one person will be required to operate the crane. Two
persons should assemble the non-engine end frame and two persons should assemble the
engine end frame.
4. Separate the assembly process into steps for the non-engine end frame and steps for the engine
end frame.
The following list shows the components that must be installed on the non-engine end frame.
{ Front Axle Housing
{ Front Drive Shaft
{ Platform for the Hand Rails
{ Lift Arms
{ Tilt Linkage
{ Tilt Cylinders
{ Front Fenders
{ Rims and Tires
{ Bucket
The following list shows the components that must be installed on the engine end frame.
{ Rear Axle Housing
{ Rear Drive Shaft
{ Bumper and Fuel Tank
{ Platform
{ Rear Fenders
{ Rims And Tires
{ Hand Rails and Ladders
{ Cab
{ ROPS
5. Arrange the work site according to Illustration 3. Arranging the work site will allow the crane
and the service truck to operate.
6. Two packing lists will be included when the machine is shipped. One packing list will be in a
plastic cover on one of the boxes. The other packing list will be inside one of the boxes. Use
the packing list in order to review the parts. Identify the parts and organize the parts. Refer to
the Parts Manual for more information.
7. Install the front axle and the rear axle. A 55 mm socket is required in order to install the front
axle and the rear axle. The 2P-2338 socket is a 55.6 mm (2.19 inch) socket. The new 4C-8217
Socket is a 55 mm (2.16 inch) socket. When the rear axle is installed, position the axle 152.4
mm (6.0 inch) from the chassis. Connect the brake lines and the fast fill service group while
the axle is in this position. The lines are much easier to connect before the rear axle is installed
on the chassis.
8. Use one of the following options in order to install the tires: tire handler, lift truck that is
equipped with sideshift and lifting slings. If lifting slings are used in order to install the tires,
do not install the front fenders or the platform assembly before the tires are installed. If the tire
handler or the lift truck are used in order to install the tires, install all of the fenders before the
tires are installed. The front fenders and the rear fenders provide easy access to the machine
during the assembly process.
9. Use chains or cables that are long enough to reach the lifting eyes on the engine end frame.
Use a spreader bar in order to lift the machine off the supports.
10. Use a lift truck that is equipped with hydraulic sideshift in order to install the rear bumper and
the fuel tank. The lift truck will offer better control of the bumper and the fuel tank during the
assembly process. The use of a lift truck will provide the operator of the lift truck and the
person that is installing the bumper with better communication.
11. Install the access ladders on the bumper and the fuel tank. Install the rear fenders. Installing
the ladders and the fenders will provide access to the top of the machine.
12. Install the platform assembly.
13. Install all of the hand rails on the following items: rear fenders, bumper, fuel tank and operator
platform. Do not install the hand rail on the front of the operator platform. Leaving the hand
rail off will provide access to the front of the machine for the entire assembly process.
14. Install the lighting to the front fenders before the front fenders are installed on the machine.
15. Use the crane or the boom on the service truck in order to install the hand rails on the hood.
16. Put a box of hand tools on top of the machine. The box of tools will prevent workers from
climbing on and climbing off of the machine in order to retrieve hand tools.
17. Use a lift truck and a pallet that was shipped with the machine as a platform for installing
components around the outside of the machine.
18. The tilt cylinders are designed to fit the left side of the machine or the right side of the
machine. Install each cylinder with the block for the cylinder rod end hydraulic line toward the
frame.
19. Torque the bolts for the ROPS to 850 ± 100 N·m (627 ± 74 lb ft).
20. Grease all of the pins in the lift linkage and in the tilt linkage before the machine is moved.
21. Drive the machine to the bucket in order to install the bucket. Move the lift arms up and down
and move the machine forward and backward in order to install the bucket.
22. Use a long pipe as a reaction bar when the bolts that hold the tire to the rim are torqued. Use a
long pipe that will react with the ground.
23. Fabricate a lifting device in order to install the collet pins in the lift linkage and in the tilt
linkage. Use lifting equipment for personnel or work from the front fenders in order to install
the pins. Refer to Illustration 4 in order to fabricate the lifting device.
24. The final step in the assembly process should be installation of the rear view mirrors and the
hand rail at the front of the platform.
Tire Inflation Pressure

Table 12
Assembly Pressure
Location Tire Size Ply Rating or Strength Index
kPa PSI
Front 49.5 × 57 42 PR 520 90
Rear 49.5 × 57 42 PR 620 75

Front 53.5 × 57 68 PR 520 90
Rear 53.5 × 57 68 PR 620 75
Note: Contact a representative of the tire manufacturer in order to determine working pressures.
Note: Valve Stems and Valve Extensions must be installed during the initial mounting and initial
inflation of the tires.
(1) 8W-0338 O-Ring Seal
(2) 5T-9796 Connector
(3) 5T-9866 Locknut
(4) 8X-2699 Extension Hose Assembly
(5) 8X-2700 Spud Assembly
(6) 5T-9797 Tire Valve
Procedure for Pinning

Table 13
Item Qty Part Number Part Description

5P-0960 Molybdenum Grease
5P-0306 Vacuum Transducer
8X-0029 Articulating Hitch Gp

1 1 8X-0149 Pin
2 1 8X-0139 Pin
3 1 8X-0145 Cover
4 2 6V-5845 Bolt
5 20 8T-4123 Plated Washer
6 1 136-4437 Spacer
7 1 8X-0146 Terminal Bushing
8 6 6V-9667 Bolt
9 1 135-6104 Locking Plate
10 1 8X-0136 Spacer
11 12 6V-9167 Bolt
12 8 6V-8132 Bolt
13 8 8T-4167 Hard Washer
14 1 8X-0148 Shim Pack
15 1 134-5788 Shim Pack
16 2 4D-0514 Pipe Plug
8X-0093 Pump Drive Shaft
17 1 8R-8510 Slip Joint
18 8 8T-0281 Bolt
19 1 168-1915 Slip Joint
20 8 9X-6480 Bolt
156-6350 Automatic Lubrication Gp

21 21 9X-8250 Clip
22 2 8T-4137 Bolt
8X-0043 Steering Frame Lock

24 1 134-5784 Pin
25 1 1J-2920 Cotter
152-8934 Transmission Control Wiring Group
26 2 8T-4179 Bolt

28 1 5P-7468 Clip
29 1 5P-7469 Clip
30 1 8T-7087 Grommet
31 1 8T-4136 Bolt
154-8015 Steering Neutralizer Valve and Mounting

33 4 8T-6466 Bolt
Unload the Machine and Prepare the Machine
1. Clean 8X-0149 Pin (1) and 8X-0139 Pin (2) .
Note: The weight of 8X-0149 Pin (1) is approximately 115.8 kg (255 lb).
Note: The weight of 8X-0139 Pin (2) is approximately 184.6 kg (407 lb).
2. Install 8X-0145 Cover (3) to 8X-0149 Pin (1) with two 6V-5845 Bolts (4) and two 8T-4123
Plated Washers (5) .
Note: Install two lifting eyes on the plate before the plate is frozen.
3. Freeze the pins or pack the pins in dry ice until the pins reach a temperature of -75 °C (-103 °
F).
4. Place the rear axle (A) into position on the work site. For more information on the location of
the rear axle, refer to Illustration 2.
Note: Place a steel plate under the blocking that supports the rear axle. The steel plate should
have the following dimensions: 1220 mm (48 inch) wide, 2440 mm (96 inch) long and 25 mm
(1 inch) thick .
5. Park the truck that is hauling the engine end frame next to the rear axle.
(B) 1219 mm (48 inch)
(C) 609 mm (24 inch)
(D) 3658 mm (144 inch)
6. Construct blocking for the engine end frame. The blocking should be 914 mm (36 inch) wide
and 1828 mm (72 inch) long. Refer to Illustration 7 for the height of the blocking.
(E) 610 mm (24 inch)
7. The blocking that supports the engine end frame should not occupy more than 610 mm (24
inch) of the frame. The space that remains under the engine end frame will be required when
the bumper and the fuel tank are installed.
Note: DO NOT attach the lifting device to the tie down points (F) on the engine end frame.
8. Attach chains or cables to a spreader bar in order to prevent damage to the hood. Place a lifting
eye in the lifting point on each side of the engine end frame. Attach the chains or the cables to
the lifting eyes (G).
9. Lift the engine end frame and place the engine end frame over the rear axle.
10. Level the engine end frame.
Note: Remove the shipping covers from the lower articulation joint on the engine end frame.
Note: Clean the bores of the upper articulation joint on the engine end frame.
11. Install 136-4437 Spacer (6) in the lower articulation joint on the engine end frame.
12. Lift the non-engine end frame off the truck. Place the frame on the ground.
Note: Remove the shipping covers from the upper articulation joint on the non-engine end
frame.
Note: Clean the bores of the lower articulation joint on the non-engine end frame.
Lift the non-engine end frame. The articulation hitches on the engine end frame and on the
non-engine end frame should be aligned.
13. Move the non-engine end frame into position in front of the engine end frame. Align the two
frames in order to install the pins in the articulation hitch.
Install the Pins in the Articulation Joints
1. Install 8X-0146 Terminal Bushing (7) .
2. Install the guide bolt (H) into the engine end frame.
3. Lift the 8X-0149 Pin into position over the upper articulation joint.
4. The pin must have the proper orientation in the upper articulation joint. Ensure that the four
holes for the steering neutralizer valves are oriented toward the rear of the machine. The 6V-
5845 Bolt (4) should be aligned with the centerline of the machine.
5. Install six 6V-9667 Bolts (8) and six 8T-4123 Plated Washers (5) into the six holes in the top
of the plate.
Note: Be careful when the lifting eyes are removed. The temperature of the pins is -75 °C (-
103 °F).
6. Remove the lifting eyes from the plate.
7. Hand tighten six 6V-9667 Bolts (8) and six 8T-4123 Plated Washers (5) .
8. Use a suitable lifting device in order to position the 8X-0139 Pin over the lower articulation
joint. Install the pin into the articulation joint.
9. Use a floor jack in order to install the 8X-0136 Spacer into the lower articulation joint.
10. Use a floor jack in order to align the 135-6104 Locking Plate (9). Mark the plate and the non-
engine end frame in order to aid in realigning the plate.
11. Install four 6V-8132 Bolts (12) and four 8T-4167 Hard Washers . The bolts and the washers
should be equally spaced around the pin.
12. Install four 6V-9167 Bolts (11) and four 8T-4123 Plated Washers .
Procedure for Installing Shims into the Lower Articulation Joint
Note: Allow the pin to return to the ambient temperature before the procedure for shimming or
the procedure for torquing are started.
Illustration 18 g00
1. Tighten the four 6V-8132 Bolts (12) to a torque of 530 ± 70 N·m (390 ± 51 lb ft).
2. Measure the gap (J) between the non-engine end frame and the 135-6104 Locking Plate (9).
Measure the gap around the entire locking plate. Subtract 0.25 mm (0.010 inch) from the
minimum thickness of the gap in order to determine the required thickness of the outer shim.
3. Install outer 8X-0148 Shim Pack (14) between the 135-6104 Locking Plate (9) and the non-
engine end frame.
4. Tighten the four 6V-9167 Bolts (11) to a torque of 300 ± 50 N·m (220 ± 37 lb ft).
5. Install two 6V-8132 Bolts (12) and two 8T-4167 Hard Washers (13). Install one bolt on one
side of the pin and the other bolt on the other side of the pin. Tighten the bolts to a torque of
530 ± 70 N·m (390 ± 51 lb ft).
6. Measure the gap between the 8X-0139 Pin (2) and the 135-6104 Locking Plate (9). Insert a
micrometer into the hole (X) in Illustration 18 in order to measure the gap. Subtract the
minimum measurement from the thickness of the 135-6104 Locking Plate that was recorded in
Step 2.
7. Install inner 134-5788 Shim Pack between the 8X-0139 Pin (2) and the 135-6104 Locking
Plate (9). The thickness of the shim pack was determined in Step 6. The tolerance for the
thickness of the shim pack is 5 mm (0.2 inch).
8. Install eight 6V-9167 Bolts (11) and eight 8T-4123 Plated Washers (5). Use an alternating
sequence in order to tighten all twelve of the 6V-9167 Bolts (11). Tighten the twelve 6V-9167
Bolts (11) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
9. Install four 6V-8132 Bolts (12) and four 8T-4167 Hard Washers . Use an alternating sequence
in order to tighten all eight of the 6V-8132 Bolts (12). Tighten the eight 6V-8132 Bolts (12) to
a torque of 800 ± 100 N·m (590 ± 74 lb ft).
10. Install two 4D-0514 Pipe Plugs (16) into two holes (X) .
11. Tighten the six 6V-9667 Bolts (8) in the upper articulation joint to a torque of 460 ± 60 N·m
(340 ± 45 lb ft).
12. Tighten the two 6V-5845 Bolts (4) in the upper articulation joint to a torque of 460 ± 60 N·m
(340 ± 45 lb ft).
Complete the Connections between the Frames
1. Install 8R-8510 Slip Joint (17) with eight 8T-0281 Bolts (18). Tighten the eight bolts to a
torque of 290 ± 20 N·m (214 ± 15 lb ft).
2. Install 168-1915 Slip Joint (19) with eight 9X-6480 Bolts (20). Tighten the eight bolts to a
torque of 530 ± 70 N·m (390 ± 52 lb ft). Use a 4C-8240 Socket with twelve points in order to
tighten the eight bolts to the specified torque.
3. Run the 114-6061 Hose As to the rear parking brake. Secure the hose with the following
items: two 9X-8250 Clips (21), two 8T-4137 Bolts (22) and two 8T-4121 Hard Washers (23) .
4. Connect the 8X-0672 Link to the non-engine end frame with one 134-5784 Pin (24) and one
1J-2920 Cotter (25) .
5. Connect the ground strap to the non-engine end frame and to the engine end frame with two
8T-4179 Bolts (26) and two 8T-4223 Hard Washers (27) .
6. Connect the wiring group for the transmission control to the wiring harness on the front frame.
Refer to Illustration 22. Secure the harness with the following items: one 5P-7468 Clip (28),
one 5P-7469 Clip (29), one 8T-7087 Grommet (30), one 8T-4136 Bolt (31) and one 8T-4121
Hard Washer (32) .
Illustration 23 g00
Note: Install a vacuum transducer on the hydraulic tank before any hydraulic lines are
connected or disconnected. Refer to ""Install the Rear Axle" ".
7. Connect the pilot lines. Refer to Illustration 23.
8. Connect 8X-5369 Hose As to the non-engine end frame at one location (K). This is a hydraulic
line for the service brakes.
9. Connect 8X-5356 Hose As to the non-engine end frame at two locations (L). This is a
hydraulic line from the brake oil cooler.
10. Connect 153-7818 Hose As to the non-engine end frame at one location (M). This is a
hydraulic line from the parking brake.
11. Connect 8X-8725 Hose As to the non-engine end frame at one location (N). This is a hydraulic
line from the hydraulic oil cooler.
12. Install the subassembly for the steering neutralizer valve with four 8T-6466 Bolts (33) and
four 8T-4121 Hard Washers (34) .
13. Connect 154-8138 Tube As to the block. Refer to Illustration 26.
Unload the Machine and Prepare the Machine (Pinned

Frames)
Note: Refer to ""Procedure for Pinning" " if the non-engine end frame and the engine end frame
were shipped separately.
Personal injury or death can result from machine articulation or

movement.
Machine frames can move and a person can be crushed.
Connect the steering frame lock link between the front and rear frames
before working on machine.
1. Place the rear axle (A) into position on the work site. For more information on the location of
the rear axle, refer to Illustration 2.
Note: Place a steel plate under the blocking that supports the rear axle. The steel plate should
have the following dimensions: 1220 mm (48 inch) wide, 2440 mm (96 inch) long and 25 mm
(1 inch) thick .
Note: DO NOT attach the lifting device to the tie down points on the sides of the non-engine
end frame.
2. Place lifting eyes in the lifting points on the top of the non-engine end frame. Attach the chains
or the cables to the lifting eyes (B) .
Note: DO NOT attach the lifting device to the tie down points (D) on the engine end frame.
3. Attach the chains or the cables to a spreader bar (C) in order to prevent damage to the hood.
Place a lifting eye in the lifting point on each side of the engine end frame. Attach the chains
or the cables to the lifting eyes (E).
4. Lift the engine end frame and place the engine end frame over the rear axle.
Note: The blocking (F) should be approximately 914 mm (36 inch)deep, 1828 mm (72 inch)
wide, and 1727 mm (68 inch) tall. The blocking will create clearance for the largest tires and
for the largest rims on the 994D Wheel Loader. The height of the blocking should be reduced
by 305 mm (12 inch) if the machine is equipped with smaller tires or smaller rims.
5. Lower the engine end frame onto the blocking (F) .
Note: The blocking (G) should be approximately 914 mm (36 inch)deep, 1828 mm (72 inch)
wide, and 1219 mm (48 inch) tall. The blocking will create clearance for the largest tires and
for the largest rims on the 994D Wheel Loader. The height of the blocking should be reduced
by 305 mm (12 inch) if the machine is equipped with smaller tires or smaller rims.
6. Lower the non-engine end frame onto the blocking (G) .
7. Remove all of the lifting devices from the machine.
Install the Rear Axle

Table 14
Item Qty Part Number Description

- - 4C-5599 Anti-Seize Compound
- - 5P-0306 Vacuum Transducer
- - 4C-4970 Tap (M36)
180-1510 Fast Fill Automatic Lubrication Service

1 1 148-8422 O-Ring Port Tee
2 1 171-6723 Elbow
8X-0041 Grease Lines Gp

3 4 148-8369 Elbow
4 2 8X-5331 Hose As
5 2 8X-5332 Hose As
8X-1741 Oscillating Axle Fastener Group
6 24 9X-2198 Bolt
7 24 3S-6162 Hard Washer
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Open the covers over the hydraulic tanks on the top of the machine.
2. Remove the air breather from the hydraulic tank for the steering system. Install a vacuum
transducer (A) onto the hydraulic tank in order to create a vacuum on the hydraulic system
while the rear axle is installed.
3. Remove the air breather from the hydraulic tank for the braking system. Install a plug (B) onto
the hydraulic tank.
4. If the machine is equipped with a 180-1510 Fast Fill Automatic Lubrication Service , install
the following items: 148-8422 O-Ring Port Tee (1) and 171-6723 Elbow (2) .
5. Clean the front and the rear machined surfaces for the rear axle that are on the engine end
frame. Use a ratchet wrench and a 4C-4970 Tap in order to clean the threads of the mounting
holes in the frame.
6. Clean the front machined surfaces (D) and the rear machined surfaces (E) on the rear axle.
7. If the rims are not installed, install lifting brackets (E) on the axle. Tighten each nut on the
lifting brackets to a torque of 408 N·m (300 lb ft). Attach chains or cables to a spreader bar in
order to prevent damage to the hood. Place a lifting eye in the lifting point on each end of the
axle. Attach the chains or the cables to the lifting eyes (F). If the rims are not installed, the
weight of the axle is 16836 kg (37120 lb). If the rims are installed, the weight of the axle is
22110 kg (48745 lb).
8. Lift the rear axle until the gap between the mounting surfaces on the axle and the mounting
surfaces on the frame is a maximum of 152 mm (6.0 inch).
9. Connect the following items to the rear axle: 103-2017 Hose As (G), 8X-5361 Hose As (H)
and 8X-5370 Hose As (J). If the machine is equipped with a 180-1510 Fast Fill Automatic
Lubrication Service , connect 125-3385 O-Ring Face Seal Hose Assembly (K) .
View of the back side of the rear axle
10. Remove two shipping plugs from the rear axle. Install the following items on the back side of
the rear axle: two 148-8369 Elbows (3) and two 8X-5331 Hose As (4) .
View of the front side of the rear axle
11. Remove two shipping plugs from the rear axle. Install the following items on the front side of
the rear axle: two 148-8369 Elbows (3) and two 8X-5332 Hose As (5) .
12. Align the machined surfaces on the rear axle and the machined surfaces on the engine end
frame. Use guide bolts and locating dowels in order to properly position the axle. For
information on the fabrication of guide bolts, refer to ""Guide Bolts that are Required for
Assembly" ".
Note: Apply 4C-5599 Anti-Seize Compound to the heads of the bolts and to the threads of the
bolts before the bolts are installed.
13. Install eight 9X-2198 Bolts (6) and eight 3S-6162 Hard Washers (7) to each mounting pad on
the back side of the rear axle.
14. Install four 9X-2198 Bolts (6) and four 3S-6162 Hard Washers (7) to each mounting pad on
the front side of the rear axle.
15. Tighten all of the bolts.
16. Place blocking between the engine end frame and the axle on both sides of the machine in
order to prevent the rear axle from shifting.
17. Use an alternating sequence in order to tighten all of the bolts. Tighten the bolts to a torque of
1600 ± 200 N·m (1180 ± 150 lb ft). Turn the bolts for an additional 120 ± 10 degrees.
Note: The plug and the vacuum transducer may remain connected for installation of the front
axle.
18. Remove the plug and the vacuum transducer from the hydraulic tanks. Install the air breathers.
Install the Drive Shaft

Table 15
- - 4C-4967 Tap (M20)

1 1 112-6548 Universal Joint
2 8 9X-6480 Bolt
1. Clean the machined surfaces on both ends of the drive shaft (1) .
2. Clean the machined surfaces on the drive shaft yoke that is on the rear axle.
3. Use a ratchet wrench and a 4C-4967 Tap in order to clean the threads of the mounting holes in
the drive shaft yoke.
4. Remove the wire (A) and the two bolts (B) .
5. Clean the machined surfaces on the drive shaft yoke that is on the back of the transmission.
Use a ratchet wrench and a 4C-4967 Tap in order to clean the threads of the mounting holes in
the drive shaft yoke.
6. Use the access area between the rear axle and the transmission in order to position the drive
shaft (1) for installation.
7. Raise the drive shaft into position. Install eight 9X-6480 Bolts .
Note: The drive shaft yokes and universal joints must be aligned with each other after
installation.
Note: The drive shaft yoke on the rear axle is mounted on a splined shaft in order to simplify
removal and installation of the drive shaft.
8. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft). Use a 4C-8240 Socket with
twelve points in order to tighten the eight bolts to the specified torque.
Install the Front Axle

Table 16

- - 5P-0306 Vacuum Transducer
- - 4C-4967 Tap (M20)
8X-1740 Fixed Axle Fastener Group
1 20 154-1586 Bolt
2 40 5T-4896 Spacer
3 20 8C-4032 Nut
8X-1721 Service Brake Lines Gp
4 1 6V-9746 O-Ring Seal
5 4 9X-6480 Bolt
NOTICE
containing fluids.

1. Clean the machined surfaces on the front drive shaft (A). Remove the shipping support (B)
from the front drive shaft.
2. Clean the locating dowels (C) and the machined surfaces (D) that are on the housing of the
front axle. Use a ratchet wrench and a 4C-4967 Tap in order to clean the threads of the
mounting holes in the housing of the front axle.
3. Clean the machined surfaces (E) that are on the non-engine end frame.
4. Clean the twenty mounting surfaces (F) for the spacers.
5. If the rims are not installed, install lifting brackets (G) on the axle. Tighten each nut on the
lifting brackets to a torque of 408 N·m (300 lb ft). Attach chains or cables to a spreader bar in
order to prevent damage to the hood. Place a lifting eye in the lifting point on each end of the
axle. Attach the chains or the cables to the lifting eyes (H). If the rims are not installed, the
weight of the axle is 16125 kg (35550 lb). If the rims are installed, the weight of the axle is
21374 kg (47120 lb).
Note: There is very little clearance between the front axle and the drive shaft. Use caution
when the front axle is installed in order to prevent damage to the drive shaft yoke.
6. Align the machined surfaces on the 8X-0132 Fixed Axle (J) and the machined surfaces on the
non-engine end frame. Use guide bolts and locating dowels in order to properly position the
axle. For information on the fabrication of guide bolts, refer to ""Guide Bolts that are Required
for Assembly" ".
Note: Apply 4C-5599 Anti-Seize Compound to the heads of the bolts and to the threads of the
bolts before the bolts are installed.
7. Install twenty 154-1586 Bolts (1) and twenty 5T-4896 Spacers to the mounting holes in the
non-engine end frame.
8. Install twenty 5T-4896 Spacers (2) and twenty 8C-4032 Nuts (3) to the twenty bolts (1) .
9. Tighten all of the nuts with an impact wrench before the crane operator removes any lifting
tension from the front axle.
10. Use an alternating sequence in order to tighten all of the bolts. Tighten the bolts to a torque of
1500 ± 150 N·m (1100 ± 110 lb ft). Turn the bolts for an additional 180 ± 10 degrees.
11. Remove the lifting devices from the front axle.
12. Install a vacuum transducer onto the hydraulic tank in order to create a vacuum on the
hydraulic system while the front axle is installed. Refer to ""Install the Rear Axle" ".
13. Remove three plugs from the brake lines on the front axle.
14. Remove one plug from each of the 8X-5391 Hose As and one plug from the 8X-5346 Hose
As .
15. Install one 8X-5391 Hose As (K) onto the front axle.
16. Install one 8X-5346 Hose As (L) with one 6V-9746 O-Ring Seal (4) onto the front axle.
17. Install one 8X-5391 Hose As (M) onto the front axle.
18. Remove the plug and the vacuum transducer from the hydraulic tanks. Install the air breathers.
19. Connect the yoke on the axle to the drive shaft yoke. Install four 9X-6480 Bolts (5). Tighten
the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft). Use a 4C-8240 Socket with twelve
points in order to tighten the four bolts to the specified torque.
20. Use a torch in order to cut the shipping support (N) from the non-engine end frame. Grind the
area that is affected by the torch until the area is smooth. Paint the area.
Install the Guards for the Brake Lines on the Front Axle
Table 17

7I-5909 Brake Line Shield Group
1 1 104-2140 Guard As
2 6 8T-4139 Bolt
4 8 8T-4192 Bolt
5 1 102-8971 Guard
6 4 8T-5001 Bolt
7 4 104-2139 Spacer
8 2 7X-2546 Bolt
10 2 104-2137 Spacer
11 2 103-0010 Bracket
12 4 8T-4136 Bolt
1 102-8970 Guard
1 104-2138 Guard As
1. Install one 104-2140 Guard As (1) to the left side of the front axle with two 8T-4139 Bolts (2)
and two 8T-4223 Hard Washers (3). Tighten the bolts to a torque of100 ± 20 N·m (75 ± 15 lb
ft).
2. Install one 102-8971 Guard (5) to the 104-2140 Guard As with four 8T-4192 Bolts (4) and
four 8T-4223 Hard Washers (3). Tighten the bolts to a torque of100 ± 20 N·m (75 ± 15 lb ft).
3. Install the following items to the guard: two 8T-5001 Bolts (6), two 104-2139 Spacers (7), two
8T-4223 Hard Washers (2), one 7X-2546 Bolt (8), one 8T-4121 Hard Washer (9) and one
104-2137 Spacer .
Note: Tighten the 8T-5001 Bolt to a torque of100 ± 20 N·m (75 ± 15 lb ft).
Note: Tighten the 7X-2546 Bolt to a torque of55 ± 10 N·m (40 ± 7 lb ft).
4. Install one 8T-4139 Bolt (2) and one 8T-4223 Hard Washer (3) to the guard. Tighten the bolt
to a torque of100 ± 20 N·m (75 ± 15 lb ft).
5. Install the following items to the boss on the machine frame: one 103-0010 Bracket (11), one
8T-4136 Bolt (12) and one 8T-4121 Hard Washer (9). Tighten the bolt to a torque of 55 ± 10
N·m (40 ± 7 lb ft).
6. Install the following items to the bracket: 102-8971 Guard (5), one 8T-4136 Bolt (12) and one
8T-4121 Hard Washer (9). Tighten the bolt to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
7. Install 104-2138 Guard As and 102-8970 Guard on the right side of the front axle. Repeat
Steps 1 through 6.
Install the Rims

Note: Disregard this section if the rims were installed at the factory. Ensure that the rim group is
torqued to the proper specification.
Table 18

1 4 - (1) Rim Group
8X-1316 Rim Mounting Gp
2 244 8T-1583 Nut
3 244 9X-8399 Washer
(1) The part number for the Rim Group is based on the size of the rim that was ordered.
2. Remove all lift brackets from the front axle and from the rear axle.
3. Steam clean the final drive (A) with Hydrosolv 100 in order to prepare the machined surface
for installation of the rim. Ensure that the machined surface is free of dirt and debris.
4. Clean both sides of the machined surface of the rim (3). Ensure that the machined surface is
free of dirt and debris.
Note: Ensure that all grease, all burrs, and all nicks are removed from the machined surfaces
on the final drive and on the rim. Use a solvent for the initial cleaning of the surfaces. Use 4C-
4188 Paint and Decal Remover for the final cleaning of the surfaces. Improper cleaning action
may result in damage to the final drive or the rim. Damage may prevent the rim from being
torqued to the proper specification.
5. Use a lift truck that is equipped with sideshift in order to install the wheel rim.
6. Position the rim (3) onto the final drive.
Note: Do not remove the support of the lift truck until a few of the nuts have been tightened.
7. Install several 8T-1583 Nuts (4) and several 9X-8399 Washers (5). Secure the nuts with an
impact wrench and a 4C-6724 Socket .
8. Install the remaining 8T-1583 Nuts (4) and 9X-8399 Washers (5). Secure the nuts with an
impact wrench and a 4C-6724 Socket .
9. Use a torque multiplier in order to tighten all of the nuts to a torque of 1300 ± 200 N·m (960 ±
148 lb ft). Turn the bolts for an additional 90 ± 5 degrees. Tighten the bolts in an alternating
sequence.
10. Repeat Step 1 through Step 9 in order to install the other three rims.
Install the Tires

Table 19

8X-1316 Rim Mounting Group
1 4 8W-0338 O-Ring Seal
2 4 5T-9796 Connector
3 4 5T-9866 Locknut
4 4 8X-2699 Extension Hose Assembly
5 4 8X-2700 Spud Assembly
6 4 5T-9797 Tire Valve
Note: Use one of the following options in order to install the tires: tire handler, lift truck that is
equipped with sideshift and lifting slings. The procedure that is described in this section is the use of
a tire handler.
2. Remove the following items from each rim: one 8W-0335 Lock Ring , one 168-4541 Bead
Seat Band and two 104-7203 Flanges .
Note: If the second flange is in the proper orientation, do not remove the flange. Continue the
installation process. Refer to Illustration 87 in order to assemble the rim.
3. Reinstall one 104-7203 Flange . Refer to Illustration 87.
4. Install the following components to the rim: 8W-0338 O-Ring Seal (1), 5T-9796 Connector
(2), 5T-9866 Locknut (3), 8X-2699 Extension Hose Assembly (4), 8X-2700 Spud Assembly
(5) and 5T-9797 Tire Valve (6) .
5. Clean the mounting area of the tire. Apply a corrosion inhibitor and a lubricant around the tire
bead.
Note: Use corrosion inhibitors and lubricants that are recommended by the tire manufacturer.
6. Investigate this step.
7. Use a tire handler in order to install the tire onto the rim.
8. Install 104-7203 Flange onto the rim.
9. Push the flange onto the rim until the 168-4541 Bead Seat Band can be installed.
10. Install one 168-4541 Bead Seat Band .
11. Install one 8W-0338 O-Ring Seal onto the rim assembly.
12. Install 8W-0335 Lock Ring .
13. Use a lift truck in order to align the components. Install 8X-2509 Driver Key .
14. Inflate the tire to the recommended pressure.
Note: Consult the tire manufacturer for the recommended tire pressure. Common tire pressure
is 90 psi in the front tires and 75 psi in the rear tires.
15. Remove the connector for the tire valve.
16. Repeat Step 2 through Step14 in order to install the other three tires.
Remove the Blocking from the Chassis
1. Place hydraulic jacks (A) under the frame (B) .
2. Lift the engine end frame (B) in order to remove the blocking (C). Remove the blocking that is
between the engine end frame and the axle before the machine is lowered to the ground.
3. Place hydraulic jacks (A) under the front axle (D). Place hardwood blocks (E) between the
jacks and the front axle.
4. Lift the non-engine end frame in order to remove the blocking (F). Lower the non-engine end
frame to the ground.
Assemble the Platform

Table 20

1 1 - (1) Platform Arrangement
2 1 152-8970 Platform Arrangement
162-2984 Operator Platform
3 1 120-7662 Channel
4 8 7X-2553 Bolt
6 1 8X-3892 Front Channel Assembly
7 8 8T-4139 Bolt
9 1 120-7657 Plate
10 19 8T-4184 Bolt
11 19 8T-4244 Nut
(1) The part number for the right hand platform is based on the configuration of the machine.
1. Position the right hand platform (1) and the left hand platform (2) .
2. Install 120-7662 Channel (3) to the left hand platform with four 7X-2553 Bolts (4) and four
8T-4122 Hard Washers (5). Do not tighten the bolts.
3. Install the 8X-3892 Front Channel Assembly (6) to the left hand platform with four 8T-4139
Bolts (7) and four 8T-4223 Hard Washers (8). Do not tighten the bolts.
4. Install 120-7657 Plate (9) to the left hand platform with the following parts: ten 8T-4184 Bolts
(10), ten 8T-4223 Hard Washers (8) and ten 8T-4244 Nuts (11) .
5. Use a lift truck that is equipped with sideshift in order to align the left hand platform and the
right hand platform.
6. Connect 120-7662 Channel (3) to the right hand platform with four 7X-2553 Bolts (4) and
7. Tighten the eight 7X-2553 Bolts (4) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
8. Connect 120-7657 Plate (9) to the right hand platform with the following parts: nine 8T-4184
Bolts (10), nine 8T-4223 Hard Washers (8) and nine 8T-4244 Nuts (11) .
9. Tighten the nineteen 8T-4184 Bolts (10) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
10. Connect 8X-3892 Front Channel Assembly (6) to the right hand platform with four 8T-4139
Bolts (7) and four 8T-4223 Hard Washers (8). Do not tighten the bolts.
11. Tighten the eight 8T-4139 Bolts (7) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
Install the Hand Rail on the Platform

Table 21

153-7968 Handhold
1 4 8X-3875 Handhold
3 48 8T-4136 Bolt
5 16 8T-4196 Bolt
1. Install two 8X-3875 Handholds (1) with twenty-four 8T-4136 Bolts (3) and twenty-four 8T-
4121 Hard Washers (4) .
2. Repeat Step 1 in order to install the hand rails on the opposite side of the machine.
3. Install 8X-3883 Handhold with eight 8T-4196 Bolts (5) and eight 8T-4121 Hard Washers (4) .
4. Repeat Step 3 in order to install the hand rail on the opposite side of the machine.
5. Tighten all of the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
6. Install the fasteners for the hand rails. Refer to ""Install the Fasteners for the Hand Rails" ".
Install the Hand Rail on the Bumper and the Fuel Tank
Table 22

153-7968 Handhold
1 2 7I-5026 Handhold

5 32 8T-4196 Bolt
6 20 8T-4136 Bolt
1. Install 7I-5026 Handhold (1) to the bumper with the following items: four 8T-4196 Bolts (5),
four 8T-4136 Bolts (6) and eight 8T-4121 Hard Washers (7) .
2. Install 7I-5027 Handhold (2) to the bumper with the following items: four 8T-4196 Bolts (5),
four 8T-4136 Bolts (6) and eight 8T-4121 Hard Washers (7) .
3. Install 7I-5024 Handhold (3) to the right side of the bumper with the following parts: eight 8T-
4196 Bolts (5), two 8T-4136 Bolts (6) and ten 8T-4121 Hard Washers (7) .
4. Repeat Step 2 and Step 3 on the opposite side of the machine. Install the following items: 7I-
5026 Handhold (1), 7I-5027 Handhold (2) and 7I-5025 Handhold (4) .
Install the Hand Rail on the Rear Fender

Table 23

1 2 152-8923 Rear Fender
153-7968 Handhold

5 96 8T-4195 Bolt
1. Remove 152-8923 Rear Fender (1) from the shipping support.
Note: Be aware of the red stripe on the fender. The side of the fender that has the red stripe is
the outside.
2. Install the following items to each fender: 8X-1362 Handhold (2), two 8X-1366 Handholds
(3), 8X-1361 Handhold (4), 48 8T-4195 Bolts (5) and 48 8T-4121 Hard Washers (6) .
Note: Use an impact wrench in order to install the bolts.
4. Repeat Step 2 and Step 3 for the other fender.
Install the Outrigger

Table 24

1 1 8X-1370 Support (RH)
2 8 8T-7338 Bolt
4 1 8X-3475 Support (LH)

5 2 8X-3900 Bracket As
6 8 7X-2552 Bolt
1. Clean the machined surfaces for the outrigger that are on the engine end frame. Use a ratchet
wrench and a 8T-3096 Tap in order to clean the threads of the mounting holes in the frame.
2. Install 8X-1370 Support (1) with four 8T-7338 Bolts (2) and four 8T-4122 Hard Washers (3) .
3. Tighten the bolts to a torque of 240 ± 40 N·m (180 ± 30 lb ft).
4. Install 8X-3900 Bracket (5) with four 7X-2552 Bolts (6) and four 8T-4122 Hard Washers (7) .
6. Clean the machined surface on the outrigger (B) in order to prepare the outrigger for
installation of the platform.
7. Repeat Step 1 through Step 6 in order to install the outrigger on the other side of the machine.
Install the Platform

Table 25

1 16 8T-4193 Bolt
3 16 8T-4132 Nut
4 8 7X-2553 Bolt
1. Clean the machined surfaces on the engine end frame (A) in order to prepare the frame for
installation of the platform.
Note: Skip this step if the machined surfaces on the outriggers have already been cleaned.
2. Clean the machined surfaces on the outriggers. Refer to ""Install the Outrigger" ".
3. Attach a suitable lifting device to the platform (B) .
4. Lift the platform (B). Position the platform over the engine end frame. Align the mounting
holes in the platform with the mounting holes on the frame and on the outriggers.
5. Install the platform to the outrigger with the following parts: four 8T-4193 Bolts (1), four 8T-
4122 Hard Washers (2) and four 8T-4132 Nuts (3). Do not tighten the bolts until all of the
bolts for the platform are installed.
6. Repeat Step 5 for the outrigger on the other side of the machine.
7. Install four 7X-2553 Bolts (4) and four 8T-4122 Hard Washers (2) to the rear of the platform.
Do not tighten the bolts until all of the bolts for the platform are installed.
8. Repeat Step 7 for the other side of the platform.
9. Install the platform to the frame with the following parts: four 8T-4193 Bolts (1), four 8T-
4122 Hard Washers (2) and four 8T-4132 Nuts (3).
10. Repeat Step 9 for the other side of the platform.
11. Tighten the sixteen 8T-4193 Bolts (1) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
12. Tighten the eight 7X-2553 Bolts (4) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
13. Connect 8X-8185 Tube As (C) to the platform with the existing hardware.
14. Connect 8X-8183 Tube As (D) to the platform with the existing hardware.
Connect the Electrical System to the Platform
1. Connect the harness for the right hand platform (A) to the harness for the engine end frame.
2. Install the negative battery cable to the platform. Route the cable through the platform.
Connect the cable to the bus bar that is located in the hydraulic compartment.
3. Connect the harness for the left hand platform (B) to the harness for the engine end frame.
4. Connect the grounding strap for the left hand platform (C) to the engine end frame.
Connect the Air Lines to the Platform
1. Connect the air supply line from the right hand platform (A) .
2. Connect the air line for the automatic lubrication system (B) .
3. If the machine is equipped with a clean out system for the cab, connect the air line (C) .
4. Connect the air line for the left hand air horn to the platform (D) .
5. Connect the air line for the left hand air horn (E) .
6. Connect the air line that is marked with a 2 to the tee (F) .
7. Connect the air line for the right hand air horn (G) .
8. Connect the air line for the auxiliary air system that is marked with a 4 to the air dryer (H) .
9. Connect the air supply line for the air compressor that is marked with a 3 to the air dryer (J) .
10. Connect the air line that is marked with a 1 to the air dryer (K) .
Install the Bumper and the Fuel Tank

Table 26

101-3756 Fuel Tank Fitting
1 1 6V-8640 Seal Connector
2 1 6V-9746 O-Ring Seal
3 1 2M-9780 O-Ring Seal
4 1 6V-8632 Connector
5 1 7J-9108 O-Ring Seal
6 1 3K-0360 O-Ring Seal
158-4539 Bumper Drawbar Arrangement
7 1 7I-5671 Bumper and Drawbar Group
8X-1379 Drawbar And Bumper Fastener Group

8 12 3S-7023 Washer
9 12 8C-3411 Bolt
7I-5671 Bumper and Drawbar Group
10 2 7I-5883 Plate
113-0672 Step Group
11 8 8T-4139 Bolt
1. Remove eight 8T-4195 Bolts (A) and eight 8T-4121 Hard Washers (B) from the lower section
of the fan guard assembly.
2. Use a lift truck or another suitable lifting device in order to remove the 8X-3470 Lower Guard
Assembly . The weight of the lower section of the fan guard assembly is 135.7 kg (300 lb).
3. Remove seven 8T-4136 Bolts (D) and seven 8T-4121 Hard Washers (E) .
4. Remove 8X-8857 Plate (F) in order to access the area that will be welded.
5. Remove the tape (G) from the fuel level sender.
6. Remove the shipping plugs (H) from the fuel lines.
7. Clean the mounting surfaces (J) on the bumper and on the fuel tank.
8. Clean the mounting surfaces (K) that are on the frame. Use a ratchet wrench and a 4C-4969
Tap in order to clean the threads of the mounting holes in the frame.
9. Install 6V-8640 Seal Connector (1) with one 6V-9746 O-Ring Seal (2) and one 2M-9780 O-
Ring Seal (3) .
10. Install 6V-8632 Connector (4) with one 7J-9108 O-Ring Seal (5) and one 3K-0360 O-Ring
Seal (6) .
11. Remove the caps (L) from two fuel lines. Remove the tie-downs from the fuel lines.
Note: A lift truck that is equipped with sideshift is recommended for the installation of the
bumper. The use of a lift truck will increase the convenience and the safety of the installation
of the bumper. If a lift truck is used to install the bumper, skip Step 12 through Step 14.
Note: If chains or cables are used to install the bumper, install guide bolts into the forward
hole on each side of the frame. For information on the fabrication of guide bolts, refer to
""Guide Bolts that are Required for Assembly" ".
12. Attach the chains or cables to a spreader bar in order to prevent damage to the hood. Attach
the chains or cables to two points on each end of the bumper.
13. Lift the bumper and align the mounting holes in the bumper with the mounting holes in the
frame.
14. Install blocking underneath the bumper. The blocking should be approximately 457 mm (18
inch) high. The blocking should not prevent the bumper from being moved for alignment.
15. Use a lift truck that is equipped with sideshift in order to move the 7I-5671 Bumper and
Drawbar Group (7) into position.
16. Lift the bumper. Align the mounting holes in the bumper with the mounting holes in the frame.
Note: Do not remove the support of the lift truck until the bolts have been tightened with an
impact wrench.
17. Install twelve 8C-3411 Bolts (8) and twelve 3S-7023 Washers (9). Tighten the twelve bolts to
a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).
Note: If chains or cables were used in order to install the bumper, remove the chains or the
cables.
18. Connect 8X-1575 Hose As (M) and 8X-1576 Hose As (P) to the fuel tank.
Note: If the machine is equipped with a fuel heater, connect 8X-1579 Hose As (M) and 8X-
157 Hose As (P) .
19. Connect the fuel level sender to the buffer for the fuel level (N) .
Note: Remove the paint from the bottom of 7I-5883 Plate (10) before the plate is welded.
20. Position 7I-5883 Plate (10) against the box section of the engine end frame.
21. Weld 7I-5883 Plate (10) to the bottom plate of the bumper.
22. Repeat Step 20 and Step 21 for the other side of the frame.
23. Install 8X-8857 Plate (F) with seven 8T-4136 Bolts (D) and seven 8T-4121 Hard Washers (E).
Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
24. Install 8X-3470 Lower Guard Assembly (C) with eight 8T-4195 Bolts (A) and eight 8T-4121
Hard Washers (B). Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
25. Install 113-0672 Step Group (11) with four 8T-4139 Bolts (12) and four 8T-4223 Hard
Washers (13). Tighten the bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
26. Repeat Step 25 for the other side of the bumper.
27. Remove the bottom screen from the left side of the radiator guard assembly.
28. Remove the shipping cover from the electrical plug. Connect the harness for the bumper (Q) to
the harness for the engine end frame.
29. Install the screen for the radiator guard assembly.
Install the Rear Fender

Note: Be aware of the red stripe on the fender. The side of the fender that has the red stripe is the
outside.
Table 27
1 2 152-8923 Rear Fender

2 16 6T-6080 Mounting
3 2 101-2659 Plate As
4 12 8X-0674 Washer
6 8 8T-6381 Bolt
7 12 8T-4139 Bolt
8 12 5P-1076 Hard Washer
9 4 6V-7688 Locknut
101-7345 Walkway
10 1 101-3302 Tread
11 4 8T-4192 Bolt
13 1 101-3301 Tread
153-7968 Handhold
14 1 101-6923 Handhold
15 1 101-6921 Handhold
16 8 8T-4136 Bolt
18 4 8T-4139 Bolt
1. If the hand rails are not installed on the rear fenders, refer to ""Install the Hand Rail on the
Rear Fender" ".
2. Install four 6T-6080 Mountings (2) to the upper mounts on the rear fender.
3. Install the following items to the bumper: four 6T-6080 Mountings (2), 101-2659 Plate As (3),
four 8X-0674 Washers (4), two 8T-4123 Plated Washers (5) and two 8T-6381 Bolts (6) .
4. Tighten the two bolts to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
5. Use a suitable lifting device in order to lift the 152-8923 Rear Fender (1). Move the fender into
position.
6. Align the mounts on the rear fender (1) with the mounts on the engine end frame.
7. Install the rear fender to the bumper with six 8T-4139 Bolts (7) and six 5P-1076 Hard
Washers (8). Do not tighten the six bolts until the bolts are installed in the upper mounts.
8. Install the rear fender to the platform with the following items: two 8X-0674 Washers (4), four
8T-4123 Plated Washers (5), two 8T-6381 Bolts (6) and two 6V-7688 Locknuts (9) .
9. Tighten the six 8T-4139 Bolts (7) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
10. Tighten the two 8T-6381 Bolts (6) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
11. Repeat Step 1 through Step 10 for the other fender.
12. Install 101-3302 Tread (10) to the engine end frame with the following hardware: two 8T-
4192 Bolts (11), two 8T-4223 Hard Washers (12) and the existing hardware (A) .
14. Install 101-6923 Handhold (14) with the following items: four 8T-4136 Bolts (16), four 8T-
4121 Hard Washers (17), two 8T-4139 Bolts (18) and two 8T-4223 Hard Washers (19) .
15. Tighten the four 8T-4136 Bolts (16) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
16. Tighten the two 8T-4139 Bolts (18) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
17. Repeat Step 12 through Step 16 for the 101-3301 Tread (13) and the 101-6921 Handhold (15) .
Install the Hand Rails on the Hood
Table 28

1 8 8X-3885 Plate
2 44 8T-4136 Bolt
4 40 8T-4196 Bolt
5 32 6V-7744 Locknut
153-7968 Handhold
7 1 133-1508 Handhold
8 1 133-1507 Handhold
1. Install eight 8X-3885 Plates (1) with 32 8T-4136 Bolts (2) and 32 8T-4121 Hard Washers (3) .
2. Install 8X-3908 Handhold (6) with the following items: sixteen 8T-4196 Bolts (4), 32 8T-
4121 Hard Washers (3) and sixteen 6V-7744 Locknuts (5) .
3. Repeat Step 2 for the other side of the machine.
4. Install one 133-1508 Handhold (7) and one 133-1507 Handhold (8) on the rear of the hood.
Install the Fasteners for the Hand Rails

Table 29

2 38 8T-4183 Bolt
3 19 115-3580 Plate
4 38 5P-7469 Clip
5 38 5P-7468 Clip
6 38 6V-1874 Grommet
7 38 8T-4244 Nut
1. Assemble nineteen fasteners for the hand rails. Refer to 162.
2. Install nineteen fasteners for the hand rails. Refer to Illustration 163.
Install the Precleaners and the Dust Ejectors

Table 30

132-9371 Air Cleaner Gp
1 4 174-7434 Plate
2 4 127-1673 Air Cleaner Adapter

3 16 101-7402 Bolt
4 16 8T-4648 Bolt
6 4 1P-9390 Outlet Gasket
7 4 103-0876 Air Cleaner Group
8 40 2K-4973 Locknut
133-6613 Precleaner Gp
10 4 7N-5973 Precleaner Body
11 4 7S-3687 Hood As
133-6503 Filter Change Indicator Gp
12 4 5M-6214 Pipe Plug
13 4 5K-5068 Fitting
14 4 3B-6552 Elbow
15 4 7W-7417 Service Indicator
129-0581 Dust Ejector Group

16 2 133-5935 Dust Ejector
17 2 7E-1397 Bent Bolt Clamp
18 5P-1471 Hose
19 8 8T-6703 Hose Clamp
20 4 5P-4325 Clip
21 4 8T-4136 Bolt
23 2 136-1612 Clip
24 2 8T-4139 Bolt
26 2 8T-4244 Nut
129-0580 Fumes Disposal Gp
27 2 175-5244 Fumes Disposal Gp
28 2 136-1612 Clip
29 8 5P-4868 Clamp
30 2 178-6365 Elbow
31 4 178-6366 Tube
32 - 5P-1261 Hose
33 2 8T-4139 Bolt
35 2 8T-4244 Nut
1. Remove two shipping covers (A) from the exhaust stacks on each side of the machine.
2. Remove four shipping plates (B) in order to install the precleaner assemblies.
3. Remove the shipping covers (C) from the fumes disposal tubes and from the dust ejectors.

Bottom View of Mounting Plate (1)
4. Before you assemble the plates clean the mounting surfaces of the plates. Refer to Illustrations
167 and 168. Install 174-7434 Plate (1) onto 127-1673 Air Cleaner Adapter (2) with four 101-
7402 Bolts (3) .
5. Install adapter assembly (2) onto the existing plate. Refer to Illustration 167. Install assembly
with four 8T-4648 Bolts (4) and four 8T-4223 Hard Washers (5) .
6. Install 1P-9390 Outlet Gasket (6) onto the adapter.
7. Remove the air filters from the 103-0876 Air Cleaner Gp (7) .
8. Install 103-0876 Air Cleaner Gp (7) to the adapter with ten 2K-4973 Locknuts (8) and ten 8T-
9. Install two filter elements in the air cleaner.
10. Install the cover onto the 103-0876 Air Cleaner Gp (7) .
11. Install 7N-5973 Precleaner Body (10) to the air cleaner group. Tighten the clamp (D) .
Note: If the machine is equipped with a custom precleaner (F), install the custom precleaner to
the precleaner body (10).
12. Install 7S-3687 Hood As (11) to the precleaner body. Tighten the clamp (E) .
13. Install the following items to the adapter (2) : 5M-6214 Pipe Plug (12), 5K-5068 Fitting (13),
3B-6552 Elbow (14) and 7W-7417 Service Indicator (15) .
Note: Install fitting (13) and elbow (14) onto the side of the adapter (2) that is opposite the
exhaust stacks.
14. Repeat Step 4 through Step 13 for the other three precleaners.
Note: The 133-5935 Dust Ejector (16) is mounted on each of the rear mufflers.
15. Install 133-5935 Dust Ejector (16) with one 7E-1397 Bent Bolt Clamp (17) .
16. Install 5P-1471 Hose (18) to the 133-5935 Dust Ejector (16) with one 8T-6703 Hose Clamp
(19) .
17. Attach 5P-1471 Hose (18) to the mounting plate for the precleaner with the following parts:
5P-4325 Clip (20), 8T-4136 Bolt (21) and 8T-4121 Hard Washer (21) .
18. Tighten the bolt to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
19. Install 5P-1471 Hose (18) to the precleaner body with one 8T-6703 Hose Clamp (19) .
20. Repeat Step 15 through Step 19 for the rear muffler on the other side of the machine.
Note: The 175-5244 Fumes Disposal Gp (27) are mounted on each of the front mufflers.
21. Install 175-5244 Fumes Disposal Gp (27) with the following parts: 136-1612 Clip (28), 8T-
4139 Bolt (33), 8T-4223 Hard Washer (34) and 8T-4244 Nut (35) .
22. Install the following items to the 175-5244 Fumes Disposal Gp : three 5P-4868 Hose Clamps
(29), 178-6365 Elbow (30), 178-6366 Tube (31) and 5P-1261 Hose (32) .
23. Remove the shipping cover from the tee that is between the crankcase breathers. Rotate the tee
by 180 degrees.
24. Install 178-6366 Tube (31) to the tee with one 5P-4868 Clamp (29) .
25. Connect the 5P-1261 Hose (32) to the 178-6366 Tube (31) with one 5P-4868 Clamp (27) .
26. Install 5P-1471 Hose (18) to the 175-5244 Fumes Disposal Gp (27) with one 8T-6703 Hose
Clamp (19) .
27. Attach 5P-1471 Hose (18) to the mounting plate for the precleaner with the following parts:
5P-4325 Clip (20), 8T-4136 Bolt (21) and 8T-4121 Hard Washer (22) .
29. Install 5P-1471 Hose (18) to the precleaner body with one 8T-6703 Hose Clamp (19) .
30. Repeat Step 21 through Step 29 for the front muffler on the other side of the machine.
31. Install plates (A) .
Install the Exhaust Extensions

Table 31

135-3879 Exhaust Extension
1 4 147-5203 Exhaust Pipe

2 24 8T-4139 Bolt
4 2 179-6061 Clamp As
5 2 190-3946 Clamp As
6 2 190-3947 Clamp As
7 2 190-3948 Clamp As
8 8 8T-4136 Bolt
10 8 6V-1874 Grommet
11 8 5P-7468 Clip
12 8 5P-7469 Clip
153-7968 Handhold
14 4 7I-5007 Pipe
15 4 8X-3178 Plate

16 8 8T-4136 Bolt
1. Install two 147-5203 Exhaust Pipes (1) with eight 8T-4139 Bolts (2) and eight 5P-1076 Hard
washers (3) .
3. Repeat Step 1 and Step 2 for the exhaust pipes on the other side of the machine.
4. Install two 7I-5007 Pipes (14) and two 8X-3178 Plates (15) with four 8T-4136 Bolts (16) and
6. Install the 8X-3884 Handhold (13) onto the 7I-5007 Pipe (14) .
Note: Do not weld the hand rails.
7. Install the following parts to the exhaust stack (1) : 179-6061 Clamp As (4), 190-3946 Clamp
As (5), 190-3947 Clamp As (6), 190-3948 Clamp As (7), four 8T-4136 Bolts (8) and four 8T-
8. Install the following parts to the hand rail (13) : four 6V-1874 Grommets (10), four 5P-7468
Clips (11) and four 5P-7469 Clips (12) .
9. Connect the four clips (11) to the four clamp assemblies with four 8T-4139 Bolts (2) .
Note: Tack weld all eight locations before completing the welding procedure in order to
ensure proper installation of the hand rails.
11. Weld the hand rail (13) at four locations.
12. Weld hand rail (14) to pipe assembly (15) at two locations (A).
13. Weld pipe assembly (15) to hood assembly at two locations (B) .
14. Repeat Step 4 Step 13 for the exhaust pipes on the other side of the machine.
Connect the Brake Control Linkage
1. Depress the left brake pedal in order to identify the cable for the transmission neutralizer (1) .
2. Depress the service brake pedal in order to identify the cable for the service brake (2) .
3. Identify the cable for the parking brake (3) .
4. Connect the cables to the brake control valve.
Install the Doors on the Platform

Table 32

162-2984 Operator Platform Gp
1 1 108-5991 Door As
2 8 8T-4136 Bolt
4 1 8X-3917 Door As
5 2 8X-5353 Rod
6 2 7J-5925 Cotter Pin
1. Install 108-5991 Door As (1) with four 8T-4136 Bolts (2) and four 8T-4222 Plated Washers
(3) .
3. Install 8X-3917 Door As (4) with four 8T-4136 Bolts (2) and four 8T-4222 Plated Washers
(3) .
5. Open the 108-5991 Door As (1). Install 8X-5353 Rod (5) onto the door assembly with 8T-
4222 Plated Washer (3) and 7J-5925 Cotter Pin (6) .
6. Open the 8X-3917 Door As (4). Install 8X-5353 Rod (5) onto the door assembly with 8T-4222
Plated Washer (3) and 7J-5925 Cotter Pin (6) .
Install the Support Plate onto the Platform

Table 33

1 8 8T-4139 Bolt
3 1 8X-7570 Plate
4 4 8T-4244 Nut
5 1 8X-7569 Plate
1. Clean the machined surfaces that are on the plate and on the engine end frame. Use a ratchet
2. Install 8X-7570 Plate (3) to the right hand platform with the following parts: two 8T-4139
Bolts (1), two 5P-1076 Hard Washers (2) and two 8T-4244 Nuts (4) .
3. Install the other end of the plate to the frame with two 8T-4139 Bolts (1) and two 5P-1076
Hard Washers (2) .
5. Clean the machined surfaces that are on the plate and on the engine end frame. Use a ratchet
6. Install 8X-7569 Plate (5) to the left hand platform with the following parts: two 8T-4139 Bolts
(1), two 5P-1076 Hard Washers (2) and two 8T-4244 Nuts (4) .
7. Install the other end of the plate to the frame with two 8T-4139 Bolts (1) and two 5P-1076
Hard Washers (2) .
Install the Side Light on the Platform

Table 34

160-4337 Flood Lighting Gp
1 2 101-8418 Bracket
2 6 8T-4136 Bolt
4 2 130-6469 Bracket
5 2 153-2073 Flood Lamp Gp
7 2 6V-9189 Locknut
8 2 8T-6869 Bolt
1. Route the wiring harness for the side light from the platform to the location of the light.
2. Install 101-8418 Bracket (1) with two 8T-4136 Bolts (2) and two 8T-4121 Hard Washers (3) .
4. If a bracket is required, install 130-6469 Bracket (4) to the 153-2073 Flood Lamp Gp (5) with
the following parts: 8T-4224 Hard Washer (6), 6V-9189 Locknut (7) and 8T-6869 Bolt (8) .
5. Install 153-2073 Flood Lamp Gp (5) to 101-8418 Bracket (1) with 8T-4136 Bolt (2) and 8T-
4121 Hard Washer (3) .
6. Tighten the nuts to a torque of 25 ± 7 N·m (18 ± 5 lb ft).
7. Connect the electrical components to the back of the 153-2073 Flood Lamp Gp (5) .
8. Repeat Step 1 through Step 7 for the side light on the other side of the machine.
Install the Brake Light

Table 35

129-0610 Stop Lighting Gp
1 2 137-7231 Housing
2 2 5I-3876 Grommet
3 8 8T-4136 Bolt
5 2 137-7237 Plate
6 16 5C-9553 Bolt
1. Remove the shipping cover from the wiring for the brake light at the rear of the machine.
Note: The lights are assembled at the factory. Install the assembly for the brake light that is
equipped with the VIMS service lamp onto the left side of the machine.
2. Install 5I-3876 Grommet (2) onto the left side of the hood assembly.
3. Install 137-7231 Housing (1) with four 8T-4136 Bolts (3) and four 8T-4121 Hard Washers
(4) .
5. Connect the wire that is black and green to the rear flood lamp (A) .
6. Connect the wire that is orange, black, and brown to the brake lamp (B). orange, black and
brown
7. Connect the wire that is black and white to the VIMS service lamp (C) .
8. Connect the wire that is black and brown to the backup alarm (D) .
9. Install 137-3237 Plate As (5) onto the housing with eight 5C-9553 Bolts (6) and eight 8T-
10. Repeat Step 1 through Step 9 for the brake lamp on the other side of the machine.
Install the Front Fenders

Table 36

1 1 121-2495 Left Hand Fender
2 1 121-2496 Right Hand Fender
158-8024 Flood Lighting Gp

3 2 111-0387 Support
4 8 9W-4361 Mount
5 16 6V-8801 Nut
7 2 2D-1290 Grommet
8 2 111-0388 Guard As
9 2 7K-1659 Grommet
10 2 9K-0700 Grommet
11 16 8T-4183 Bolt
13 2 4P-7581 Clip
14 2 8T-4195 Bolt
16 2 9X-6772 Cable Strap

17 10 7X-2563 Bolt
1. Place 111-0387 Support (3) into a suitable holding device.
2. Install the following parts: four 9W-4361 Mounts (4), four 6V-8801 Nuts (5) and four 8T-
3. Install 2D-1290 Grommet (7) into the 111-0388 Guard As (8) .
Note: The plug for the auxiliary light (A) should be oriented toward the outside of the
machine.
Note: Route the wiring harness through 2D-1290 Grommet and through 111-0387 Support
before mounting the 111-0388 Guard As .
4. Install 111-0388 Guard As (8) onto 111-0387 Support with four 6V-8801 Nuts (5) and four
8T-4896 Hard Washers (6) .
5. Install 7K-1659 Grommet (9) into 111-0387 Support .
6. Install 9K-0700 Grommet (10) into 121-2495 Left Hand Fender (1) .
7. Install 111-0387 Support (3) onto the 121-2495 Left Hand Fender (1) with eight 8T-4183
Bolts (11) and eight 8T-4223 Hard Washers (12) .
9. Install 4P-7581 Clip (13) with 8T-4195 Bolt (14) and 8T-4121 Hard Washer (15) .
Note: Leave the 8T-4195 Bolt (14) loose until the fender is installed. After the fender is
installed, secure the harness with 9X-6772 Cable Strap (16) .
10. Use a suitable lifting device in order to lift the fender and position the fender on the non-
engine end frame.
11. Install the 121-2495 Left Hand Fender (1) to the non-engine end frame with five 7X-2563
Bolts (17) and five 8T-4123 Plated Washers (18) .
12. Tighten the five bolts to a torque of 460 ± 60 N·m (340 ± 45 lb ft).
13. Connect the 158-7878 Harness to the harness for the non-engine end frame.
14. Secure the harness. Refer to Step 9.
15. Repeat Step 1 through Step 14 for the fender on the other side of the machine.
Location of the Receptacles for Optional Lighting
The machine is equipped with four receptacles for optional lighting. The receptacles are plugged in
order to prevent the plugs from being contaminated when the machine is shipped. If the receptacles
are not used, leave the plugs in the receptacles.
Clean the Steering Cylinders
Remove the shipping grease from the steering cylinder rods (A) before the machine is turned.
Install the Cab

Table 37

154-8015 Steering Neutralizer Valve and Mounting
1 1 8X-3186 Bracket
2 2 8T-4779 Bolt
4 2 8X-3467 Stud Assembly
5 2 8T-4244 Nut
6 4 8E-0841 Mount
7 8 8T-7338 Bolt
9 2 8T-6380 Bolt
11 2 9W-7388 Washer
1. Remove 7X-2549 Bolt (A) from the articulation hitch.
2. Install 8X-3467 Stud Assembly (4) and 8T-4244 Nut (5) onto 8X-3186 Bracket (1) .
3. Install 8X-3186 Bracket (1) to the engine end frame with two 8T-4779 Bolts (2) and two 8T-
5. Tighten the 7X-2549 Bolt (A) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
Note: Apply grease to the bore of each support before the 8E-0841 Mount (6) is installed.
6. Install four 8E-0841 Mounts (6) onto the supports for the cab.
7. Clean the machined surfaces on the cab and on the engine end frame.
8. Install four 138-7573 Link Brackets (B) to the top of the cab. Attach chains or cables to the
four link brackets.
9. Use a suitable lifting device in order to lift the cab and position the cab. The weight of the cab
is 876 kg (1930 lb).
10. Connect 109-9786 Hose As (C). Connect 109-9787 Hose As (D).
11. Connect the outlet hose for the heater (E) with 5D-1026 Hose Clamp .
12. Connect the inlet hose for the heater (F) with 5D-1026 Hose Clamp .
13. Install the cab to the engine end frame with eight 8T-7338 Bolts (7) and eight 8T-4122 Hard
Washers (8) .
14. Tighten the eight bolts to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
15. Install the following parts to the 8E-0841 Mount : 8T-6380 Bolt (9), 8T-4167 Hard Washer
(10) and 9W-7388 Washer (11) .
17. Remove the shipping plugs (G) from the bottom of the cab and from the steering neutralizer
lines.
18. Install the following parts: 154-9647 Hose As (H), 154-9649 Hose As (J), 154-9648 Hose As
(K) and three 6V-8398 O-Ring Seals .
19. Connect the following parts: 154-9652 Hose As (L), 154-9650 Hose As (M), 154-9651 Hose
As (N) and 3K-0360 O-Ring Seal .
20. Connect seven hoses for the implement pilot circuit to the bottom of the cab.
21.
22. Connect the harness for the left hand platform to the cab.
23. Connect the chassis harness to the cab.
24. Connect the transmission harness to the cab.

Platform and the rear of the cab
25. Connect the chassis harness to the harness for the left hand platform.
26. Install the windshield wiper to the front of the cab.
Install the ROPS Floodlights

Table 38

160-4340
1 8 153-2073 Flood Lamp Gp
2 8 6V-9189 Locknut
4 8 8T-6869 Bolt
5 8 130-6469 Bracket
6 8 9X-9365 Lamp Bracket
7 16 8T-4136 Bolt
1. Remove the shipping covers from the harnesses on the ROPS.
2. Install the following parts to eight 153-2073 Flood Lamp Gp (1) : eight 6V-9189 Locknuts (2),
sixteen 8T-4224 Hard Washers (3), eight 8T-6869 Bolts (4), eight 130-6469 Brackets (5),
eight 9X-9365 Lamp Brackets (6), eight 8T-4136 Bolts (7) and 8T-4121 Hard Washers (8) .
4. Install the floodlights to the ROPS with eight 8T-4136 Bolts (7) and eight 8T-4121 Hard
Washers (8) .
Note: Connect the wire that is yellow and black to the floodlight that is on the outside edge of
the ROPS.
6. Connect the harness on the ROPS to the floodlights.
Install the ROPS

Table 39

1 1 165-4011 Rollover Protective Structure (ROPS) Gp
165-4012 ROPS Fastener Group

1 60 3E-9850 Bolt
2 60 3S-7023 Washer
3 60 118-5584 Spacer
1. Remove the shipping bolts (A) from the shipping support.
2. Clean the machined surfaces that are on the ROPS and the machined surfaces that are on the
frame. The mounting surfaces should be free of paint, clean, and dry when the ROPS is
installed.
3. Use a ratchet wrench and a 4C-4969 Tap in order to clean the threads of the mounting holes
(B) in the frame.
4. Attach chains or cables to the ROPS.
5. Use a suitable lifting device in order to lift the ROPS and position the ROPS. The weight of
the ROPS is 3150 kg (6945 lb).
6. Install the following parts to the ROPS: sixty 3E-9850 Bolts (2), sixty 3S-7023 Washers (3)
and sixty 118-5584 Spacers (4). Tighten sixty bolts with an impact wrench.
7. Tighten sixty bolts to a torque of 850 ± 100 N·m (630 ± 75 lb ft).
8. Connect the harness for the cab to the harness for the ROPS (C) .
Install the Platform Covers
Table 40

1 2 8X-4732 Plate
2 38 8T-4136 Bolt
4 1 8T-4133 Nut
5 1 8X-3870 Bracket
6 1 8X-3873 Bracket
7 1 8X-3865 Bracket
8 1 8X-3868 Bracket
9 1 8X-3864 Bracket
10 1 8X-4524 Plate As
11 4 8T-4137 Bolt
1. Install one 8X-4732 Plate (1) with five 8T-4136 Bolts (2) and five 8T-4121 Hard Washers
(3) .
2. Repeat Step 1 for the other side of the machine.
3. Install one 8X-3870 Bracket (5) on the left hand side of the cab with the following parts: six
8T-4136 Bolts (2), twelve 8T-4121 Hard Washers (3) and six 8T-4133 Nuts (4) .
4. Install one 8X-3873 Bracket (6) on the right hand side of the cab with the following parts: six
8T-4136 Bolts (2), twelve 8T-4121 Hard Washers (3) and six 8T-4133 Nuts (4) .
5. Install one 8X-3865 Bracket (7) on the left hand side of the cab with the following parts: four
8T-4136 Bolts (2), eight 8T-4121 Hard Washers (3) and four 8T-4133 Nuts (4) .
6. Install one 8X-3868 Bracket (8) on the right hand side of the cab with the following parts: four
8T-4136 Bolts (2), eight 8T-4121 Hard Washers (3) and four 8T-4133 Nuts (4) .
7. Install one 8X-3864 Bracket (9) to the platform with the following parts: four 8T-4136 Bolts
(2), eight 8T-4121 Hard Washers (3) and four 8T-4133 Nuts (4) .
8. Install one 8X-4524 Bracket (10) to the platform with the following parts: four 8T-4137 Bolts
(11), four 8T-4121 Hard Washers (12), four 8T-4136 Bolts (2) and eight 8T-4121 Hard
Washers (3) .
Install the Lift Arms

Table 41

- - 5P-0960 Molybdenum Grease
1 1 8X-0741 (1) Arm and Bearing

2 - 103-1814 Shim
3 - 103-1815 Shim
4 1 9U-3298 Guard As
(1) The part number for the lift arm assembly will depend on the type of lift arms that are installed.
1. Remove the following parts from the lift arm pivot: one 3E-8011 Bolt (A), two 9X-8399
Washers (B) and 8T-1583 Nut (C) .
Note: The parts that were removed will be required during the installation procedure.
2. Attach chains or cables to the lift bracket.
3. Use forcing bolts in order to remove the 154-7204 Collet (E) .
Note: Use a hammer on the other end of the lift arm pivot in order to force the collet out of the
bore.
4. Use a lifting device in order to remove 8X-0660 Pin (F). Remove lifting bracket (D) .
Note: Disconnect 8X-1351 Hose As (G) in order to remove the inner 154-7204 Collet (E) that
is on the right hand side of the machine.
5. Use a bar in order to force the other 154-7204 Collet (E) out of the bore. Do not damage the
inside of the collet during the removal process.
6. Repeat Step 1 through Step 5 for the lift arm pivot on the other side of the frame.
7. Attach chains or cables to the lift arm assembly.
8. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and
free of rust. Check the lift arm assembly and the non-engine end frame. Clean the four 154-
7204 Collets (E) and the two 8X-0660 Pins (F) .
9. Before you install the pin, lubricate the inside diameter of each bearing, each collar, and
the outside diameter of the pin with clean 80W90 EP gear oil. This will make assembly
easier and this will prevent dry spots between the pin and the bearings.
10. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual,
RENR2038.
11. Carefully fill the pin joint with the recommended lubricant. Pin joints that are equipped with
lip seals should be manually filled with grease. Continue to fill the pin joint until the grease is
forced out of the pin and each seal.
12. DO NOT rely on the automatic lubrication system (if equipped) in order to initially fill
the new pin joint.
13. Use a suitable lifting device in order to position the lift arm assembly. The weight of the lift
arm assembly is approximately 22309 kg (49185 lb).
Note: The gap (H) between the lift arm assembly and the non-engine end frame should be
equal on both sides of the lift arms.
14. Insert 103-1814 Shim (2) or 103-1815 Shim (3) into the gap on both sides of the lift arm
assembly. Insert the same size of shims and the same number of shims on both sides of the lift
arm assembly in order to equalize the gap (H) .
Note: Do not force the shims into the gap (H) .
15. Record the number of shims and the size of shims that are installed in the gap.
16. Repeat Step 14 and Step 15 for the lift arm pivot on the other side of the frame.
17. Use a lifting device in order to install two 8X-0660 Pins (F) .
18. Measure the distance between the end of the pin and the non-engine end frame. Position the
pin in the bore so that there is an equal space on each end of the pin.
Note: Apply 4C-5599 Anti-Seize Compound to the inner diameter of the collets.
19. Install two 154-7204 Collets to each pin. The collets on each end of the pin should extend the
same distance from the non-engine end frame.
20. Install 9U-3298 Guard As (4). Position the guard assembly so that the opening for the lever
assembly faces the front of the machine. Turn the guard assembly until the lower edge of the
guard assembly is horizontal.
Note: Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.
21. Install the following parts to the lift arm pivot: one 3E-8011 Bolt (A), two 9X-8399 Washers
(B) and 8T-1583 Nut (C) .
Note: As the bolt is tightened, each collet should extend the same distance from the non-
engine end frame.
23. Strike the collets and the lift arm pivot with a hammer until the bolt torque drops to 950 N·m
(700 lb ft).
25. Strike the collets and the lift arm pivot with a hammer until the bolt torque drops to 1600 N·m
(1180 lb ft).
Note: Torque the bolts after the machine has operated for eight hours and after the machine
has operated for fifty hours.
27. Repeat Step 21 through Step 26 for the lift arm pivot on the other side of the machine.
28. Lower the lift arms (1) onto two suitable jack stands. Remove all of the lifting devices from
the lift arms.
Install the Lift Arm Position Sensor

Table 42

1 1 216-6952 Bail Arm
2 2 8T-4779 Bolt
3 2 9X-8257 Hard Washer
4 2 6D-3025 Ball Bearing
5 2 2L-6726 Retaining Ring

6 1 4E-2250 Housing
7 1 4E-2453 Governor Control Shaft
8 1 2H-3429 Retaining Ring
9 3 8C-5608 Spacer
10 6 8C-5607 Mount
11 1 161-8904 Position Sensor
12 2 6V-2313 Bolt
13 2 4B-4274 Washer
14 3 7X-7888 Bolt
15 9 9X-6165 Washer
16 3 9U-3300 Spacer
17 1 6S-4868 Lever
18 1 8T-2502 Bolt
20 2 8K-1253 Rod End
21 4 6V-8186 Full Nut
22 1 5D-9372 Rod
24 1 3D-8752 Locknut
25 1 9U-4474 Plate
26 3 4M-5281 Bolt
1. Install 216-6952 Bail Arm (1) on block (A) with two 8T-4779 Bolts (2) and two 9X-8257
Washers (3) .
2. Install two 6D-3025 Bearings (4) and two 2L-6726 Retaining Rings (5) into 4E-2250 Housing
(6) .
3. Install 4E-2453 Shaft (7) through the front of 4E-2250 Housing (6) and through bearings (4) .
4. Install 2H-3429 Ring (8) on shaft (7) .
5. Install one 8C-5608 Spacer (9) and two 8C-5607 Mounts (10) in each of the three holes in
housing (6) .
6. Install 161-8904 Position Sensor (11) to the back of the housing (6) with two 6V-2313 Bolts
(12) and two 4B-4274 Washers (13) .
7. Place housing (6) in position on guard assembly (B). Install three 7X-7888 Bolts (14), six 9X-
6165 Washers (15), and three 9U-3300 Spacers (16) .
Note: Additional 9X-6165 Washers (15) may be added for extra clearance between the
housing (6) and the head of the bolt. Install the additional washers between the 9U-3300
Spacer (16) and the 8C-5607 Mount (10) .
Note: Place the lift arms in the lowest position. Tilt the bucket fully.
8. Install 6S-4868 Lever (17) on shaft (7) with one 8T-2502 Bolt (18) and one 8T-4896 Washer
(19) .
Note: Do not tighten bolt (18) at this time.
9. Install two 6V-8186 Full Nuts (21) and one 8K-1253 Rod End (20) on each end of 5D-9372
Rod (22) .
Note: The distance between the jam nuts should be 187 mm (7.4 inch).
10. Lengthen the rod by four turns of each rod end (20) .
11. Install one 8T-4224 Washer (23) and one 3D-8752 Locknut (24) to the sensor end of the rod
(22). Install rod (22) between lever (17) and bail arm (1). Tighten the bolt (18) which retains
the lever (17) .
12. Remove rod (22). Shorten the rod by turning each rod end four times. Install rod (22) between
lever (17) and bail arm (1). Tighten one 6V-8186 Full Nut (21) on each rod end.
Note: Shortening the rod prevents the sensor from bottoming out.
13. Install 9U-4474 Plate (25) to guard assembly with three 4M-5281 Bolts (26) and three 5P-
4115 Washers (27) .
14. Connect the wire from the position sensor to the harness for the front frame. Secure the wires
with several 9X-6772 Cable Straps .
Connect the Lift Cylinders

Table 43

1 2 8X-0662 Pin
2 2 156-5916 Collet
3 2 156-5917 Collet
4 2 3E-8009 Bolt
5 2 9X-8399 Washer
6 2 6V-8628 Elbow
Note: The grease port on the rod end of the lift cylinder should be oriented toward the front of
the machine.
1. Attach cables or chains to the lift arms (A). Use a suitable lifting device to raise the lift arms.
2. Raise the lift arms until the lift cylinder pin bore is clear of the frame.
free of rust.
RENR2038.
the new pin joint.
8. Extend the lift cylinder until the rod eye is aligned with the pin bore on the lift arm. Install 8X-
0662 Pin (1) .
9. Measure the distance between the end of the pin and the lift arm. Position the pin in the bore
so that there is an equal space on each end of the pin.

Rod End of Left Hand Lift Cylinder

Rod End of Left Hand Lift Cylinder
10. Install 156-5916 Collet (2) into the pin bore on the inner side of the lift arm.
11. Install 156-5917 Collet (3) into the pin bore on the outer side of the lift arm.
Note: The collets on each end of the pin should extend the same distance from the lift arm.
12. Install 3E-8009 Bolt (4) with 9X-8399 Washer (5). The bolt threads should engage the threads
on the inside of the 156-5916 Collet .
Note: Start the bolt from the inside collet on the lift arm.
Note: As the bolt is tightened, each collet should extend the same distance from the lift arm.
14. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to 950
N·m (700 lb ft).
16. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to
1600 N·m (1180 lb ft).
18. Install 6V-8628 Elbow (6) with 3J-7354 O-Ring Seal (7). Connect the grease line from the
non-engine end frame to the elbow (6) with 4J-5477 O-Ring Seal (8) .
19. Repeat Step 8 through Step 18 for the lift cylinder on the other side of the machine.
20. Grease the rod end of the lift cylinder manually.
21. Lower the lift arms to the ground.
Assemble the Tilt Cylinders
Table 44

8X-1399 Tilt Cylinder Lines Gp
1 2 1P-3706 Seal
2 2 8X-1341 Block
3 4 5P-8077 Half Flange
5 8 8T-4779 Bolt
6 8 7X-2559 Bolt
7 2 8X-1342 Bracket
8 2 1P-3707 Rectangular Seal
9 1 8X-1348 Tube As
10 8 8T-4173 Bolt
11 1 8X-1349 Tube As
13 1 8X-5782 Hose As
14 4 5P-8077 Half Flange
15 8 8T-4140 Bolt
17 2 8X-1354 Hose As
18 1 8X-1353 Hose As

19 8 5P-2322 Lip Seal
Note: The tilt cylinders are designed to fit the left side of the machine or the right side of the
machine. Install each cylinder with the block for the cylinder rod end hydraulic line toward the
frame.
1. Clean the pin bores on the rod end and on the head end of the tilt cylinder.
2. Remove the shipping cover.
3. Install 1P-3706 Seal (1) into 8X-1341 Block (2) .
4. Install 1P-3705 Rectangular Seal (12) into 8X-5782 Hose As (13) .

Bottom View of Tilt Cylinders
5. Install the following parts onto the tilt cylinder: 8X-5782 Hose As (13), two 5P-8077 Half
Flanges (14), 8X-1341 Block (2), four 7X-2559 Bolts (6) and four 8T-4122 Hard Washers
(4) .
Note: Do not tighten the bolts until the other end of the hose is secured.
6. Install 8X-1342 Bracket (7) with two 8T-4779 Bolts (5) and two 8T-4122 Hard Washers (4) .
7. Remove the shipping cover.
8. Install 1P-3707 Rectangular Seal (8) into 8X-1348 Tube As (12) .
9. Install 8X-1348 Tube As (12) onto the cylinder with four 8T-4173 Bolts (10) .
10. Install the other end of the 8X-1348 Tube As (12) to the bracket (7) with two 8T-4779 Bolts
(5) and two 8T-4122 Hard Washers (4) .
11. Tighten the bolts with an impact wrench. Tighten the bolts to a torque of 240 ± 40 N·m (180 ±
30 lb ft).
12. Install 1P-3705 Rectangular Seal (12) into 8X-1354 Hose As .
13. Attach the 8X-1354 Hose As (17) to the 8X-1348 Tube As (12) with the following parts: two
5P-8077 Half Flanges (14), four 7X-2559 Bolts (6) and four 8T-4122 Hard Washers (4) .
Note: Do not tighten the bolts until the other end of the hose is secured.
14. Install four 5P-2322 Lip Seals (19) into the bores of the tilt cylinder.
15. Repeat Step 1 through Step 14 for the tilt cylinder on the other side of the machine.
Install the Tilt Cylinders

Table 45


1 4 1V-8031 Pin
2 8 8R-3931 Collet
3 4 3E-8010 Bolt
4 8 9X-8399 Washer
5 4 8T-1583 Nut
6 2 8X-3497 Hose As
8 2 6V-8628 Elbow
1. Clean the bores for the tilt cylinders on the non-engine end frame.
free of rust.
RENR2038.
the new pin joint.

Right Hand Tilt Cylinder
7. Use a suitable lifting device in order to lift the tilt cylinder and position the tilt cylinder.
Note: The grease port on the head end of the tilt cylinder should be oriented upward. The
grease port on the rod eye of the tilt cylinder should be oriented downward.
8. Align the pin bore in the head end of the tilt cylinder (A) with the pin bore on the non-engine
end frame.
9. Use a suitable lifting device in order to lift 1V-8031 Pin (1). Install the pin into the pin bore.
10. Measure the distance between the end of the pin and the non-engine end frame. Position the
pin in the bore so that there is an equal space on each end of the pin.
11. Install two 8R-3931 Collets (2) into the pin bore on each end of the pin.
Note: The collets on each end of the pin should extend the same distance from the non-engine
end frame.

Head End of Left Tilt Cylinder
12. Install 3E-8010 Bolt (3) with 9X-8399 Washer (4) .
Note: Start the bolt from the inside collet on the tilt cylinder.
13. Install 9X-8399 Washer (4) and 8T-1583 Nut (5) to the bolt.
engine end frame.
15. Strike the collets and the tilt cylinder head with a hammer until the bolt torque drops to 950
N·m (700 lb ft).
17. Strike the collets and the tilt cylinder head with a hammer until the bolt torque drops to 1600
N·m (1180 lb ft).
19. Use a come-along (B) in order to position the tilt lever so that the rod end of the tilt cylinder
can be installed.
20. Attach chains or cables to the tilt cylinder. Use a suitable lifting device in order to align the pin
bore on the rod end of the tilt cylinder.
free of rust.
RENR2038.
25. DO NOT rely on the automatic system (if equipped) in order to initially fill the new pin
joint.
26. Use a suitable lifting device in order to lift 1V-8031 Pin (1). Install the pin into the pin bore.
27. Install two 8R-3931 Collets (2) into the pin bore on each end of the pin.
Note: The collets on each end of the pin should extend the same distance from the tilt lever.
28. Install 3E-8010 Bolt (3) with 9X-8399 Washer (4) .
29. Install 9X-8399 Washer (4) and 8T-1583 Nut (5) to the bolt.
engine end frame.
31. Strike the collets and the rod end of the tilt cylinder with a hammer until the bolt torque drops
to 950 N·m (700 lb ft).
33. Strike the collets and the rod end of the tilt cylinder with a hammer until the bolt torque drops
to 1600 N·m (1180 lb ft).
35. Install one 8X-3497 Hose As (6) to the rod eye with the following parts: 4J-5477 O-Ring Seal
(7), 6V-8628 Elbow (8) and 3J-7354 O-Ring Seal (9)
36. Repeat Step 7 through Step 18 for the other tilt cylinder.
Install the Tilt Cylinder Lines

Table 46


3 2 8X-7657 Hose As
4 2 148-8369 Elbow
1. Remove four flanges (A) and four covers (B) from the non-engine end frame. Illustration 291
only shows two of the covers and two of the flanges.
2. Connect two 8X-1354 Hose As (D) with two 1P-3705 Rectangular Seals (1) .
3. Connect 8X-1353 Hose As (E) with one 1P-3704 Rectangular Seal (2) .
4. Connect 8X-5782 Hose As (F) with one 1P-3704 Rectangular Seal (2) .
5. Tighten the bolts that are on the other end of the four hose assemblies. Tighten the bolts to a
torque of 240 ± 40 N·m (180 ± 30 lb ft).
6. Install one 8X-7657 Hose As (3) to each of the tilt cylinders with one 148-8369 Elbow (4) .
Connect the Bucket to the Lift Arms

Table 47

1 2 178-6246 Seal Plate
2 4 178-6242 Collar
3 2 178-6241 Bearing
4 6 133-2149 Shim Pack
5 2 7X-2550 Bolt

7 8 8T-4187 Bolt
9 2 178-6248 Plate
10 2 178-6245 Pin
11 4 9X-7699 Lip Seal
12 2 147-2001 Bolt
13 2 9X-8259 Washer
14 2 8X-0712 Plate
1. Clean the pin bores on the lift arms and on the bucket.
free of rust.
RENR2038.
the new pin joint.
7. Tighten 8T-0667 Bolt (A) in order to spread the pin bore.
Note: Do not tighten the bolt to a torque higher than 542 N·m (400 lb ft).
8. Install the 178-6241 Bearing (3) into the pin bore.
9. When assembling, or reassembling the bucket pin components, it is necessary that 8X-0712
Plate (14) be installed so that contact against the outside diameter of bearing (3) is maintained.
If plate (14) is not properly installed, it is possible for the grease to leak out of the joint.
10. Use a rod with a small diameter in order to ensure that the grease port in the bearing is aligned
with the hole in the lift arm.
11. Measure the distance between each end of the bearing and the edge of the lift arm.
12. Center the bearing in the pin bore.
Note: The bearing should not extend more than 3 mm (0.1 inch) past the edge of the pin bore.
13. Install 9X-7699 Lip Seal (11) into the grooves on the ends of the 178-6241 Bearing (3) .
14. Loosen the bolts (A) that were used to spread the pin bore in the lift arm.
15. Tighten four 6V-8198 Bolts (C) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).
16. Repeat Step 1 through Step 15 for the other lift arm.
Note: Apply 4C-5599 Anti-Seize Compound to the outer diameter of the collars.
17. Install four 178-6242 Collars (2) into the bores in the hinge plates on the bucket.
Note: Install the collars with the counterbore toward the lift arm.
18. Align the pin bores in the lift arms with the bores in the hinge plates on the bucket.
free of rust.
RENR2038.
the new pin joint.
24. Install 178-6245 Pin (10) .
25. Install 178-6246 Seal Plate (1) with 147-2001 Bolt (12) and 9X-8259 Washer (13) .
26. Install 178-6248 Plate (9) with four 8T-4187 Bolts (7) and four 8T-4123 Plated Washers (8) .
27. Insert 133-2149 Shim Pack (4) in order to eliminate gaps between the flag retainer and the
bracket on the bucket.
28. Install 7X-2550 Bolt (5) and 8T-4223 Hard Washer (6) .
29. Tighten the four 8T-4187 Bolts (7) to a torque of 2700 ± 300 N·m (2000 ± 220 lb ft).
30. Tighten the 7X-2550 Bolt (5) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
Note: While the autolube system is actuated, move the implements slowly until all of the
implements have been cycled through the full range of motion several times.
Install the Tilt Link

Table 48

1 8 5L-5032 O-Ring Seal
2 4 138-9325 Collar
3 8 1R-1056 Seal
4 2 138-9320 Pin
5 4 4I-5006 Spacer
6 4 9X-8399 Washer
7 4 8T-0368 Bolt
8 4 138-9329 Plate
9 12 9X-8257 Washer
10 12 8T-4193 Bolt
11 4 114-9275 O-Ring Seal
12 4 138-9326 Collar
13 2 138-9322 Pin
Connect the Tilt Link to the Bucket
Note: The part number for the tilt link will depend on the lift arms that are on the machine.

Cutaway of the Bucket End of the Tilt Link
1. Clean the 138-9325 Collar (2). Place the collars on a work bench so that the groove for the O-
ring seal is oriented upward.
2. Assemble four 1R-1056 Seals (3) .
3. Install one 1R-1056 Seal (3) into the large groove on each 138-9325 Collar (2) .
Note: Install the seal so that the load ring is inside the groove on the collar and the lip seal is
facing away from the collar.
4. Install one 5L-5032 O-Ring Seal (1) into the small groove on the other end of each collar.
5. Install one 138-9325 Collar (2) into each bore on the bucket.
Note: The end of the collar with the 5L-5032 O-Ring Seal should face the outside of the bore.

Orientation of Tilt Link
6. Use a suitable lifting device in order to lift the tilt link. Align the pin bore in the tilt link with
the pin bores on the bucket.
free of rust.
RENR2038.
the new pin joint.
12. Install 138-9320 Pin (4) into the pin bore. Start the pin from the outside pin bore on the bucket.
13. Install 114-9275 O-Ring Seal (11) into the groove on the end of the 138-9320 Pin (4) .
14. Install the following items into the flag retainer on the 138-9320 Pin (4) : 4I-5006 Spacer (5),
9X-8399 Washer (6) and 8T-0368 Bolt (7) .
16. Install 138-9329 Plate (8) with three 9X-8257 Washers (9) and three 8T-4193 Bolts (10) .
18. Add lubricant to the pin joint through the grease port in the tilt link.
19. Check the air void with a 9U-7960 Void Meter . The air void should be 25 kPa (100 inch of
H2O).
Note: Do not overfill the cavity in the pin joint. An air space is required in the pin joint in
order to allow the oil to expand as heat is added.
20. Repeat Step 6 through Step 19 for the other tilt link.
Connect the Tilt Link to the Tilt Lever
Note: The part number for the tilt link will depend on the lift arms that are on the machine.

Cutaway of the Bucket End of the Tilt Link
1. Clean the 138-9326 Collar (12). Place the collars on a work bench so that the groove for the
O-ring seal is oriented upward.
2. Assemble four 1R-1056 Seals (3) .
3. Install one 1R-1056 Seal (3) into the large groove on each 138-9326 Collar (12) .
Note: Install the seal so that the load ring is inside the groove on the collar and the lip seal is
facing away from the collar.
4. Install one 5L-5032 O-Ring Seal (1) into the small groove on the other end of each collar.
5. Install one 138-9326 Collar (12) into each bore on the tilt lever.
Note: The end of the collar with the 5L-5032 O-Ring Seal (1) should face the outside of the
bore.

Orientation of Tilt Link
6. Use a suitable lifting device in order to lift the tilt link. Align the pin bore in the tilt link with
the pin bores on the bucket.
free of rust.
RENR2038.
the new pin joint.
12. Install 138-9322 Pin (13) into the pin bore. Start the pin from the outside pin bore on the
bucket.
13. Install 114-9275 O-Ring Seal (11) into the groove on the end of the 138-9322 Pin (13) .
14. Install the following items into the flag retainer on the 138-9322 Pin (13) : 4I-5006 Spacer (5),
9X-8399 Washer (6) and 8T-0368 Bolt (7) .
16. Install 138-9329 Plate (8) with three 9X-8257 Washers (9) and three 8T-4193 Bolts (10) .
18. Add lubricant to the pin joint through the grease port in the tilt link.
19. Check the air void with a 9U-7960 Void Meter . The air void should be 25 kPa (100 inch of
H2O).
Note: Do not overfill the cavity in the pin joint. An air space is required in the pin joint in
order to allow the oil to expand as heat is added.
20. Repeat Step 1 through Step 19 for the other tilt link.
Install the Lift Kickout

Table 49

8X-0032 Kickout and Positioner
1 1 8X-1521 Plate
2 1 8X-1519 Magnet Assembly

3 2 4L-6454 Bolt
5 2 3K-7092 Spring Nut As
6 1 214-9196 Guard As
7 4 8T-4136 Bolt
1. Remove the shipping covers from the grease lines at the lift arm pivot. Connect the grease
lines to the lift arms.
2. Repeat Step 1 for the other lift arm pivot.
3. Position 8X-1521 Plate (1) on the right hand lift arm pivot. Elbow (D) should be centered in
the notch at the top of the plate. The bottom of the notch in the plate should be 19.05 mm (0.75
inch) behind the elbow.
4. Weld 8X-1521 Plate (1) to the lift arm.
5. Install 8X-1519 Magnet Assembly (2) to the plate with the following parts: two 4L-6454 Bolts
(3), two 8T-4121 Hard Washers (4) and two 3K-7092 Spring Nut As (5) .
6. Install 214-9196 Guard As (6) with four 8T-4121 Hard Washers (4) and four 8T-4136 Bolts
(7) .
Install the Tilt Kickout

Table 50

8X-1536 Kickout and Positioner
1 1 8X-1519 Magnet Assembly
2 1 183-3753 Bucket Positioner Mounting Gp
3 7 8T-4195 Bolt
5 1 2A-6834 Block
6 1 2A-6833 Clamp As

8 6 8T-4244 Nut
9 1 117-7464 Bracket
10 4 8T-4779 Bolt
12 1 2A-6836 Tube As
13 2 5T-1831 Clamp
14 4 7X-2549 Bolt
15 1 112-8220 Harness
16 1 9G-0116 Bucket Positioner Control
17 1 9G-9152 Clip
18 1 8X-1525 Cover As
19 1 8T-4189 Bolt
21 1 5C-7261 Nut
22 1 3V-6909 Block
23 4 8T-4136 Bolt
24 2 8T-8911 Bolt
25 1 053-6410 Retainer
26 1 5P-2369 Clip
27 1 4K-8302 Clip
28 7 8T-4133 Nut
29 5 8L-8137 Clip
30 6 9M-8406 Clip
31 1 8C-7528 Clip
1. Install 8X-1519 Magnet Assembly (1) to 183-3753 Bucket Positioner Mounting Gp (2) with
two 8T-4195 Bolts (3) and two 8T-4121 Hard Washers (4) .
2. Install 183-3753 Bucket Positioner Mounting Gp (2) to the tilt cylinder with the following
parts: 2A-6834 Block (5), 2A-6833 Clamp As (6), two 8T-4223 Hard Washers (7) and two
8T-4244 Nuts (8) .
3. Install 117-7464 Bracket (9) to the tilt cylinder with four 8T-4779 Bolts (10) and four 8T-
5. Install 2A-6836 Tube As (12) with the following parts: two 5T-1831 Clamps (13), four 7X-
2549 Bolts (14), eight 8T-4223 Hard Washers (7) and four 8T-4244 Nuts (8) .
7. Run the 112-8220 Harness (15) through the 2A-6836 Tube As (12) .
8. Connect 9G-0116 Bucket Positioner Control (16) to 112-8220 Harness (15) .
9. Install 9G-9152 Clip (17) into 8X-1525 Cover As (18) with the following parts: 8T-4189 Bolt
(19), two 8T-4224 Hard Washers (20) and 5C-7261 Nut (21) .
11. Install 3V-6909 Block (22) with two 8T-4136 Bolts (23) and two 8T-4121 Hard Washers (4) .
12. Secure the wiring for the tilt kickout to the cover (18) with the clip (17) that was installed in
Step 9.
13. Install 9G-0116 Bucket Positioner Control (16) to 8X-1525 Cover As (18) with two 8T-8911
Bolts (24) and two 8T-4224 Hard Washers (20) .
Note: The clearance adjustment for the magnet (1) and the bucket positioner control (16) is 8
± 2 mm (0.32 ± 0.08 inch).
14. Install 053-6410 Retainer (25), 5P-2369 Clip (26), and 4K-8302 Clip (27) with the following
parts: two 8T-4136 Bolts (23), 8T-4121 Hard Washer (4) and 8T-4133 Nut (28) .
16. Install five 8L-8137 Clips (29) and five 1S-0724 Clips (30) to the 8X-1354 Hose As (A) with
the following parts: five 8T-4195 Bolts (3), five 8T-4121 Hard Washers (4) and five 8T-4133
Nuts (30) .
18. Remove one bolt (B) from the valve assembly. Install 8C-7528 Clip (31) to the 112-8220
Harness (15). Secure the clip with the bolt that was removed.
Adjust the Tilt Kickout
1. Park the machine on a surface that is hard and smooth. Lower the bucket to the ground.
2. Loosen two nuts (A) in order to adjust the position of the magnet.
Note: The centerline of the magnet should be ± 10 degrees from the centerline of the tilt
cylinder.
3. Tighten two nuts (A) .
4. Loosen four bolts (B) in order to adjust the position of the tube assembly.
Note: The front edge of the control group should be aligned with the back edge of the magnet.
5. Tighten four bolts (B) .
6. Loosen two bolts (C) on the bucket positioner control in order to adjust the gap between the
sensor and the magnet.
Note: The clearance adjustment for the magnet (1) and the bucket positioner control (16) is 8
± 2 mm (0.32 ± 0.08 inch).
7. Align the centerline of the control group with the centerline of the magnet.
8. Tighten two bolts (C) .
Install the Front Hand Rail

Table 51

153-7968 Handhold

2 8 8T-4136 Bolt
1. Install 8X-3880 Handhold (1) with eight 8T-4136 Bolts (2) and eight 8T-4121 Hard Washers
(3) .
2. Tighten the eight bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
Note: The front hand rail is installed last in order to allow access to the front of the machine
during the assembly process.
Install the Mirrors
Table 52

- - 107-0257 Mirror
107-0256 Mirror
1 1 4E-8122 Tube
2 1 4E-8123 Tube
3 3 7F-1866 Bolt
5 1 7I-3720 Tube
6 1 8V-8908 Plate As
7 2 5S-7383 Bolt
8 2 7I-3722 Clip
9 1 5P-6879 Mirror
10 2 4L-6454 Bolt
11 3 6V-8801 Nut
12 1 8V-8901 Plate
13 2 8T-4956 Bolt
15 1 106-4144 Bracket
16 1 8T-9377 Bolt
17 3 7X-0325 Bolt
18 3 8T-4648 Bolt
1. Install 4E-8122 Tube (1) to 4E-8123 Tube (2) with one 7F-1866 Bolt (3) and one 8T-4896
Hard Washer (4) .
3. Install 7I-3720 Tube (5) with two 7F-1866 Bolts (3) and two 8T-4896 Hard Washers (4) .
5. Install 8V-8908 Plate As (6) with two 5S-7383 Bolts (7) and two 8T-4896 Hard Washers (4) .
7. Install two 7I-3722 Clips (8) .
8. Install 5P-6879 Mirror (9) with the following parts: two 4L-6454 Bolts (10), two 8T-4896
Hard Washers (4) and two 6V-8801 Nuts (11) .
Note: Adjust the mirror so that the door can be opened and closed without interference.
10. Install 8V-8901 Plate (12) with two 8T-4956 Bolts (13) and two 8T-4223 Hard Washers (14) .
12. Install 106-4144 Bracket (15) with the following parts: two 8T-9377 Bolts (16), two 8T-4896
Hard Washers (4) and two 6V-8801 Nuts (11) .
14. Install 107-0256 Mirror to the cab with three 7X-0325 Bolts (17) and three 8T-4223 Hard
Washers (14) .
Note: Use one bolt (17) in order to secure 106-4144 Bracket (15) to the cab.
16. Install three 8T-4648 Bolts (18) and three 8T-4223 Hard Washers (14) .
18. Repeat Step 1 through Step 17 for the other mirror.
Install the Transmission Guards

Table 53

8X-0026 Transmission Guard Gp
1 1 8X-0726 Guard
2 1 8X-0725 Guard
8X-1736 Bottom Guard Fastener Group
3 17 8T-5439 Washer
4 17 8T-6430 Bolt
1. Use a lift truck or a suitable lifting device in order to lift the 8X-0726 Guard (1). The weight of
the guard is approximately 105 kg (232 lb).
2. Install 8X-0726 Guard (1) with seven 8T-6430 Bolts (4) and seven 8T-5439 Washers (3) .
3. Use a lift truck or a suitable lifting device in order to position the 8X-0725 Guard (2). The
weight of the guard is approximately 171 kg (377 lb).
4. Install 8X-0725 Guard (2) with ten 8T-6430 Bolts (4) and ten 8T-5439 Washers (3) .
5. Tighten all seventeen of the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
Remove the Shipping Brackets
Note: Do not remove the shipping brackets until the assembly process is complete and the
machine is ready to be put into service.
1. Use a torch in order to remove each of the four shipping brackets.
2. Grind the area that is affected by the torch until the area is smooth.
3. Paint the area.
Procedure for Starting the Machine

1. Connect the steering frame lock link.
Note: Refer to Operation and Maintenance Manual, SEBU7145, "Lubricant Viscosities and
Refill Capacities" for information on the fluids.
2. Fill the fuel tank to 25 percent capacity in order to keep the weight to a minimum.
3. Check the engine oil level. Maintain the engine oil at the correct level.
4. Fill both of the radiators with coolant.
5. Fill all three of the hydraulic tanks with hydraulic fluid.
6. Fill the final drives and the differentials with oil.
7. Check the oil level in the front pump drive. Maintain the oil at the correct level.
8. Disconnect the case drain lines from three implement pumps. Fill the case drain lines with oil.
9. Disconnect the case drain lines from two steering pumps. Fill the case drain lines with oil.
10. Disconnect the case drain line from the brake actuation pump. Fill the case drain line with oil.
11. Fill the transmission with oil. The transmission oil level should be at the full mark on the
dipstick.
12. Use an external source in order to fill the air tank. The engine will need approximately 800
kPa (116 psi) in order to start.
Note: After the machine has been operated the engine will only require 650 kPa (95 psi) in
order to start. The capacity of the air tank will allow the engine to be started three times.
13. Turn the electrical disconnect switch to the ON position.
14. Turn the engine start switch to the ON position. Do not turn the engine start switch to the
START position.
15. Check the VIMS system for the correct alarms and for the correct lights.
Note: Refer to Operation and Maintenance Manual, SEBU7145, "Functional Test (VIMS
Monitoring System)" for information on the VIMS self test.
Note:
16. Check on the machine and around the machine in order to verify that the machine is clear of
personnel and clear of equipment.
Note: Refer to Operation and Maintenance Manual, SEBU7145, "Walk-Around Inspection".
17. Pull the remote engine stop switch. Hold the switch out.
18. Turn the engine start switch to the START position. Hold the switch in the START position
for ten seconds.
19. Repeat Step 17 and Step 18 three times.
20. Check all of the fluid levels. Maintain the fluids at the correct level.
21. Push the remote engine stop switch back to the RUN position.
22. Start the engine. Run the engine at low idle for ten to twenty seconds.
Note: Do not operate the implement controls or the STIC.
23. Stop the engine and check all of the fluid levels. Maintain the fluids at the correct level.
24. Repeat Step 22 and Step 23 until the fluid levels do not change.
Break-In Procedure (Pin)
1. Start with the bucket level on the ground. Slowly raise the boom to the level position. Check
that pins (B) and (A) are at the same height.
2. Slowly move the bucket to the maximum RACK position of the tilt cylinder. Check the
maximum angle of the rack control position.
3. Slowly move the bucket to the maximum DUMP position of the tilt cylinder. Move the bucket
back to the horizontal position.
4. Lower the bucket to the ground. Apply enough downward pressure in order to lift the front
tires off the ground. Release the downward pressure in order to lower the front tires to the
ground.
5. If the machine is equipped with lip seals lubricate the new pin joints manually in order to force
the grease between the pins and the seals. If the machine is equipped with face seals lubricate
the new pin joints manually in order to force the grease from the relief fitting. On machines
that are equipped with an automatic lubrication system, the system can be activated manually
in order to grease the new pin joints. On machines that are equipped with pins that are filled
with oil, manual lubrication is not necessary.
6. Repeat Step 1 through Step 5 five more times.
7. Start with the bucket level on the ground. Slowly raise the boom to maximum lift height.
8. Slowly move the bucket to the maximum RACK position of the tilt cylinder.
9. Slowly move the bucket to the maximum DUMP position of the dump stops.
10. Move the bucket back to the horizontal position. Lower the bucket to the ground. Apply
enough downward pressure in order to lift the front tires off the ground. Release the downward
pressure in order to lower the front tires to the ground.
11. Refer to Step 5.
13. After the last lift and tilt cycle, lubricate ALL of the linkage pins.
14. Move the machine to a pile of loose material. Load the bucket until the bucket is half full.
Raise the loaded bucket to the level position. Dump the bucket.
ground.
18. Use the same pile of loose material and load the bucket until the bucket is half full. Raise the
loaded bucket to maximum lift height.
19. Dump the bucket. Lower the bucket to the ground. Apply enough downward pressure in order
to lift the front tires off the ground. Release the downward pressure in order to lower the front
tires to the ground.
23. Use the same pile of loose material and load the bucket with a normal heaped load. Raise the
loaded bucket to maximum lift height. Dump the bucket.
ground.
28. On machines that are equipped with an automatic lubrication system, refill the lubricant
reservoir.
29. Stop the engine and check all of the fluid levels. Maintain the fluids at the correct level.
30. After all of the implements have been operated, purge all of the air from the implement pilot
system.
Operation after Break-In Procedure (Pin)
1. Check the new pin joint for noise or unusual motion for several shifts. Check after the pin joint
is replaced.
2. On machines that are equipped with an automatic lubrication system, make sure that the
system is lubricating the pin joints at the correct interval.
3. Check for fresh grease at the seals of the pin joint, if the machine is equipped with lip seals.
Check for fresh grease at the relief fitting, if the machine is equipped with face seals.
4. If the machine is equipped with an automatic lubrication system, reduce the lubrication
interval after a pin joint is replaced.
5. On machines with manually lubricated pin joints, lubricate the new pin joint at the middle and
the end of each shift for several days after a pin joint is replaced.
Purge the Brakes
NOTICE
containing fluids.

1. Place a container under the brake valve in order to contain any brake fluid that is lost when the
brakes are purged.
2. Open the brake purge valve (1) on the right front brake.
3. Depress the brake pedal in the cab. Release the brake pedal.
4. Repeat Step 2 until all of the air is purged from the brake line.
5. Depress the brake pedal. Close the brake purge valve (1) .
6. Repeat Step 1 through Step 5 for the brake purge valves on the other three brakes.
Adjust the Steering Neutralizer Valve

Note: The steering neutralizer valves prevent contact between the engine end frame and the non-
engine end frame.
Note: Remove the steering lock link before the neutralizer valve is adjusted.
Initial Adjustment of the Steering Neutralizer Valve
1. Park the machine on a surface that is hard and smooth.

Left Steering Neutralizer Valve

Left Turn Frame Stop
2. Turn the machine all the way to the left.
3. Adjust steering neutralizer screw (1) in order to set the gap between the steering stop on the
non-engine end frame (3) and the steering stop on the engine end frame (4) to 100 mm (4
inch).
4. Repeat Step 2 and Step 3 for the steering neutralizer screw on the right side of the machine.
Check the Adjustment of the Steering Neutralizer Valve
1. Place a 25 mm (1 inch) ball of putty onto the left steering stop (3) that is on the non-engine
end frame.
2. Place the transmission in neutral and start the engine.
3. Raise the empty bucket. The lift arm pin (A) and the bucket pin (B) should be at the same
height.
4. Disengage the parking brake and the service brakes.
5. Run the engine at high idle.
6. Turn the machine all the way to the left.
7. Steer the machine so that the machine is in the straight ahead position. Engage the parking
brake. Stop the engine.
8. Measure the thickness of the putty. The putty should not be pressed to a thickness that is less
than 4 ± 1 mm (0.16 ± 0.04 inch).
9. If necessary, adjust steering neutralizer screw (1) until the dimension is correct.
10. Repeat Step 1 through Step 9 for the right steering stop.
Fast Fill Automatic Lubrication Service (If Equipped)
1. Open the cover on the right side of the engine end frame.
(1) Air Pressure Gauge
(2) Autolube Fill Indicator
(3) Autolube Reservoir
(4) Radiator and Aftercooler
(5) Jacket Water Cooler
(6) Power Train Oil Cooler
(7) Pressurized Air
(8) Engine Crankcase Oil
(9) Implement Hydraulic Oil
(10) Brake Cooler Oil
(11) Steering and Brake Oil
Commissioning Procedure
Make sure that all of the fluid levels are properly filled before the commissioning procedures begin.
Check the machine systems. Make sure that the systems are within specifications before the machine
is put in service.
Make sure that the steering stops are adjusted to a 100 mm (4.0 inch) gap.
Reference: Refer to Special Instruction, "Check the Adjustment of the Steering Neutralizer Valve"
for additional information.
Articulate the machine. Grease the upper drive shaft and the lower drive shaft across the hitch.
The list that follows shows the recommended assembly checks for the machine. The list also shows
the recommended system checks for the machine. Perform the checks before the machine is
delivered to the customer. Mark the list "YES" when the system functions properly. Mark the list
"NO" when the system malfunctions. Record the information on the pages at the rear of this manual.
Refer to the Service Manual in order to correct any system malfunction. Any system malfunction
must be corrected before the machine is delivered.
The following information covers the testing procedures for the 994D Wheel Loaders.
Modify the VIMS Configuration of the Machine
Modifications of the VIMS configuration is necessary when the machine is first delivered. Modify
the machine configuration in order to match the conditions at the job site (shifts, volume of the
bucket, material, etc).
Note: In order to modify the machine configuration, the software in the Vehicular Off-Board Bundle
(VOB) must be installed on a personal computer. The VOB is shipped separately from the machine.
The software in the VOB will be used to modify the machine configuration. Refer to Dealer License,
JERD2137 for the installation instructions for the software. The reference also shows the instructions
for the use of the software.
Note: The customer should complete the Customer Defined VIMS Payload Information Form prior
to the commissioning procedure and payload calibration. The machine configuration should be
customized to the customer's specification.

The graphic shows the sequence of the modification of the machine configuration. The graphic shows the steps for the
payload calibration.
Copy Configuration
1. Connect the computer to the service port with a 127-9797 Cable Assembly .
2. Start the VIMS Communicate icon.
3. Copy the configuration file from the machine. Open "Configure", and select Copy
Configuration.
4. Save the configuration file for the machine on the computer.
5. Close the VIMS Communicate icon.
Modify the Machine Configuration with the User Defined

VIMS Payload Information
1. Start the Information System Builder.
2. Import the configuration file for the machine. Open "File", and select "Import".
3. Enter the location or another identifier.
4. Perform the initial setup of the payload system. Open "Navigate", and select "Setup Loader
Payload".
Note: Refer to the Information System Builder Manual for specific instructions in order to
customize the configuration file with the Customer Defined VIMS Payload Information.
5. Export the configuration file for the machine which was previously modified. Open "File", and
select "Export".
6. Close the Information System Builder.
Load the Updated File for the Machine Configuration
NOTICE
Uploading the configuration file erases all onboard data. If the data is
needed, download the data before uploading the updated configuration
file.
1. Start the VIMS Communicate icon.
2. Load the configuration file for the machine which was previously modified. Open
"Configuration", and select "Upload".
3. Reset the Time and the Date.
4. Assign the equipment number from the User Defined VIMS Payload Information Form.
5. Close the VIMS Communicate icon and disconnect the computer from the machine.
Set Product ID Serial Number, Transmission Serial Number,

and Torque Converter Serial Number
Illustration 379 g
Set the Product ID serial number, the transmission serial number, and the torque converter serial number.
Use the Caterpillar ET service tool to set the Product IDserial number, the Transmission serial
number, and the Torque Converter serial number.
1. In ET, go to the "Service" icon and select the "Configuration Screen". Select the "Product ID"
and set the serial number for the machine. Select the "Transmission Serial Number" and set the
correct value. Select the "Torque Converter Serial Number" and set the correct value.
2. Set the maximum allowable transmission gear for each direction and set all operating
conditions. Select "Transmission Maximum Forward Gear" or "Transmission Maximum
Reverse Gear" and set the correct value. The ECM will default to third speed forward and third
speed reverse. A tattletale value keeps track of changes to the maximum allowable
transmission gear.
Power Train
Engine
1. Run the engine at normal operating temperature and place the transmission in NEUTRAL.
Engine speed at high idle should be 1700 ± 50 rpm. Engine speed at low idle should be 750 ±
30 rpm. Verify the idle speeds according to the values on the engine performance
specification. See the engine information plate for the values. Full load rpm should be 1600 ±
10 rpm.
2. Stall the torque converter. Boost pressure is specified as 123 kPa (18 psi) (105 to 142 kPa (15
to 21 psi)). The boost pressure can also be specified by 890 mm (35 inch) of HG (785 to 1065
mm (30.9 to 41.9 inch)).
3. Oil pressure should be 159 to 600 kPa (23 to 87 psi) at low idle speed. Oil pressure should be
331 to 600 kPa (48 to 87 psi) at full load.
4. Operate the machine at the full load rpm of 1600 ± 10 rpm. Fuel pressure should be 415 to 450
kPa (60 to 65 psi).
Torque Converter
Note: The machine must be at normal operating temperature for the following calibration.
1. Calibrate the torque converter by using the VIMS keypad module and the VIMS display
window.
Use the VIMS keypad module and type in the letters "SERV". Press the "OK" key.
VIMS will provide a list of service modes for the entire machine one at a time. Use the "<"
key or the ">" key in order to view the different service modes.
Follow the instructions on the VIMS display in order to complete the calibration.
For additional information, refer to Testing and Adjusting, RENR2506, "994D Wheel Loader
Power Train".
2. Torque Converter Stall
NOTICE
Do not keep the torque converter in a stall condition for long periods of
time. Damage could occur in the torque converter, the engine, and the
brakes.

The pressure tap is located on the torque converter case on the right side of the machine.
a. Install a hose and a 1400 kPa (200 psi) pressure gauge on pressure tap (A) .
b. Engage the parking brake, and place the transmission in NEUTRAL. Start the engine.
c. Display the engine rpm on the VIMS display window.
d. Be sure that the high idle rpm for the engine is correct at 1700 ± 50 rpm. Be sure that the
power train oil is at normal operating temperature.
e. Apply the service brakes with the service brake pedal. Release the parking brake.
f. Shift the transmission into THIRD SPEED REVERSE.
g. Slowly increase the engine rpm to full throttle. The machine will try to move.
Note: Put the machine against a solid object that will not move, if the brakes will not
keep the machine from moving.
h. The engine rpm should be 1547 ± 65 rpm with the torque converter in the stall
condition.
i. The pressure on the gauge should be 345 to 550 kPa (50 to 80 psi).
j. Shift the transmission to NEUTRAL and bring the power train oil temperature back to
the normal operating temperature.
k. Stop the engine and remove the test equipment.
3. Torque Converter Lockup Clutch

The pressure tap is located on the torque converter case on the left side of the machine.
a. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap (B) .
b. Move the lockup clutch switch to the ENABLE position.
c. Engage the parking brake, and place the transmission in NEUTRAL. Start the engine.
d. Apply the service brakes and release the parking brake. Place the machine in SECOND
SPEED FORWARD.
e. Operate the machine at maximum speed, and observe the pressure reading on the gauge.
Make sure that the left service brake pedal or the right service brake pedal are not
depressed. If the left service brake pedal or the right service brake pedal are depressed
the lockup clutch will not engage. The maximum stabilized pressure should be 2205 ±
345 kPa (320 ± 50 psi).
4. Torque Converter Impeller Clutch Pressure

The pressure tap is located on the torque converter case on the left side of the machine.
a. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap (C) .
b. Engage the parking brake, and place the transmission in NEUTRAL. Start the engine.
c. Move the reduced or maximum rimpull switch to the MAXIMUM position.
d. Operate the engine at high idle speed and observe the pressure reading on the gauge.
The maximum pressure should be 2500 kPa (363 psi).
e. Operate the engine at high idle speed and completely depress the left pedal. Observe the
pressure reading on the gauge. The default setting is 500 kPa (73 psi). The setting is
adjustable between 250 kPa (36 psi) to 680 kPa (100 psi).
5. Torque Converter Inlet Pressure "P3"

The pressure tap is located on top of the transmission at the front of the transmission.
a. Connect a hose to nipple (D). Connect a 1400 kPa (200 psi) pressure gauge to the
opposite end of the hose.
b. Start the engine and run the engine at high idle.
c. The pressure on the gauge must not exceed 930 kPa (135 psi) with cold oil.
Transmission
1. Bring the engine and the transmission to normal operating temperatures, and put the
transmission in NEUTRAL.
a. Operate the engine at high idle speed. The speed clutch pressure tap "P1" (2) should be
2650 ± 140 kPa (385 ± 20 psi).
b. Operate the engine at high idle speed. The direction clutch pressure tap "P2" (1) should
be 2170 ± 105 kPa (315 ± 15 psi).
c. Operate the engine at high idle speed. The transmission lubrication pressure tap (3)
should be 140 kPa (20 psi).
d. Operate the engine at low idle speed. The transmission lubrication pressure tap "P3" (3)
should be no less than 7 kPa (1 psi).
e. The differential pressure is the difference between the "P1" and "P2" values. The
differential pressure should be 380 ± 35 kPa (55 ± 5 psi).
f. The torque converter inlet pressure P3 should be 1619 kPa (235 psi).
2. Partially depress the left pedal. The impeller clutch must slip in all gears. Torque converter
output should be 25% of the torque at the lockup clutch.
3. The transmission control switch must operate correctly in each gear.
4. The backup alarms must activate immediately when the transmission control lever is shifted
into reverse. The alarms must be clearly audible and the alarms must function until the
transmission is returned to NEUTRAL.
Differential and Final Drive
Fill the oil reservoir to the proper level. Operate the machine at full throttle in first gear for a
minimum of 1.5 minutes. Operate the machine in both forward and reverse directions under these
conditions.
1. The oil compartments must not leak.
2. No unusual noises should be coming from the machine.
Parking Brakes and Service Brakes
1. The alert indicator will be red when the brake system pressure is below 6900 kPa (1000 psi).
2. Engage the parking brake. Move the transmission from the NEUTRAL position and select any
gear. The alert indicator will sound intermittently.
Note: The transmission control lever must be held in a gear position in order to activate the
alarm.
3. Engage the parking brake. The brake system pressure must be in the normal range. The alert
indicator will be red.
Air System
1. Connect a 0 to 1380 kPa (0 to 200 psi) pressure gauge.
2. Start the engine.
3. Use a 3R-4825 Control Valve in order to drain the air tank.
4. The cut-in pressure should be a minimum of 655 kPa (95 psi).
5. Stop draining the air tank.
6. The pressure for the cut-out should be 828 ± 34 kPa (120 ± 5 psi).
Tires
Inflate the rear tires to a working pressure of 520 kPa (75 psi). Inflate the front tires to a working
pressure of 655 kPa (95 psi). Consult with the representative from the tire manufacturer for
recommended tire pressures for your working conditions.
Hydraulics
Steering Check
NOTICE
Purge the air in the cylinders by slowly stroking the cylinders ten times
in both directions. If the cylinders have not been purged of air, do not
bottom out the rod stroke at either end. Air in the cylinders can
damage the cylinder seals.
1. Operate the engine at high idle speed. The system pressure should be 3755 ± 1240 kPa (545 ±
180 psi) when the STIC is not active.
2. Place the machine on a dry level concrete surface. Release the brakes, and run the engine at
high idle speed. Separate the steering frame lock in order to steer the machine.
a. The turning time between the right turn stop and the left turn stop should be 4.1 to 4.5
seconds.
b. The difference between steering left and steering right should be no more than 0.3
seconds.
c. Apply the service brakes and measure the turning time between the right turn stop and
the left turn stop. The time must not vary more than 0.3 seconds from the time in Step
2.a.
d. Adjust the neutralizer stems so that there is a 100 mm (4.0 inch) gap between the stops
of the frame at a full left turn or a full right turn. Refer to Special Instruction, "Adjust
the Steering Neutralizer Valve" for more information.
3. Place the machine on a dry level concrete surface, and release the brakes. Place the machine in
the straight ahead position with the bucket slightly off the ground. The hydraulic oil
temperature should be 21° to 43°C (70° to 109°F), and the engine should be at low idle speed.
Move the STIC slowly to the right at a rate which barely causes articulation. Stop the motion
of the STIC and allow the STIC to return to the NEUTRAL position. The machine should not
articulate more than 3 degrees after the STIC returns to the NEUTRAL position.
Supplemental Steering
1. Operate the machine in an open area at the maximum forward ground speed.
2. Shift the transmission into NEUTRAL.
3. Stop the engine.
The machine should be easy to steer. The machine should respond in a similar manner as an
operating machine. The steering response will decrease as the machine slows to a stop.
Pilot Controls
1. Operate the engine at low idle speed. The pilot pressure should be 2400 ± 40 kPa (348 ± 6
psi).
2. Operate the engine at high idle speed and place the transmission in the NEUTRAL position.
The bucket must be empty. Move the lift control lever and the tilt control lever in all possible
operating positions. The lift function and tilt function should operate properly.
3. Operate the engine at low idle speed and place the transmission in the NEUTRAL position.
The bucket must be empty. Move the lift control lever and the tilt control lever in all possible
operating positions. The lift function and tilt function should operate properly.
4. Operate the engine at high idle speed. The control levers must remain in the NEUTRAL
position. The lift cylinders and the tilt cylinders must not move.
5. A force of 15 to 45 kPa (3 to 10 psi) is required to pull the control levers out of the RAISE
position, the FLOAT position, and the TILT BACK DETENT position. The measurement
should be taken as close to the knob of the control lever as possible.
6. Operate the engine at high idle speed. The lift control lever and the tilt control lever must
operate freely in the partial shift position or the full shift position.
Implement
1. Connect three gauges with quick disconnects to the pumps. Use 51700 kPa (7500 psi) gauges.
Operate the engine at high idle speed, and tilt back the bucket completely. Read the pressures
on all three gauges. All three pressures should be 30400 ± 500 kPa (4400 ± 75 psi).
Note: The oil temperature should be 52 °C (125 °F) at high idle speed.
Note: Do not overheat the hydraulic fluid during this procedure.
Start the engine. Make sure that high pressure does not exist in the system.
2. Operate the engine at high idle speed. Place the transmission in NEUTRAL, and make sure
that the bucket is empty.
a. The time that is required to raise the empty bucket from the ground to the end of the lift
cycle should be 12 to 13 seconds.
b. Fully extend the lift cylinders. The time that is required to move the bucket to the dump
stop from the full tilt back position should be 3.6 to 4.5 seconds.
3. Check the cylinder drift after the bucket is attached.
a. Fully extend the lift cylinders. The maximum allowable cylinder rod drift is no more
than 20 mm (.79 inch) in 5 minutes.
b. Fully extend the lift cylinders and make the bucket level with the ground. The maximum
allowable cylinder rod drift is no more than 25 mm (1.0 inch) in 5 minutes.
c. The allowable drift rates are for oil temperatures of 38° to 49°C (100° to 120°F). See
Table 54 for additional information.
Table 54
HYD OIL TEMP LIFT TIME TILT TIME
2.7 sec 2.7 sec

49° to 66°C (120° to 150°F) 20 mm (.79 inch) 25 mm (.98 inch)
Above
2.7 sec 1.7 sec
66 °C (150 °F) 20 mm (.79 inch) 25 mm (.98 inch)
Brake Accumulator Charging Valve
1. Operate the engine at low idle speed. The accumulator pressure must increase to 15500 to
16500 kPa (2250 to 2395 psi).
2. Check the actuation pressure for the brakes at the brake control group. The actuation pressure
should be 8620 ± 350 kPa (1250 ± 50 psi) while the right brake pedal or the left brake pedal is
depressed. The residual pressure in both cases should be a maximum of 140 kPa (20 psi).
Purge the brakes at each wheel.
Leakage
Clean all oil from the connections and the fittings. Move all cylinders through the full range of
motion. Hold the control levers in the open position at the end of the stroke in order to obtain relief
valve pressure. Inspect all lines, connections, fittings, and cylinder rod seals for leaks.
Note: Do not hold the relief valve pressure for more than 10 seconds when the cylinders reach the
end of the stroke. If more time is needed to conduct the test, do not increase the pressure for at least
one minute.
Operator's Module
Steering Control
1. Operate the engine at high idle speed. Move the stick to the right. The machine must articulate
to the right.
2. Operate the engine at high idle speed. Move the stick to the left. The machine must articulate
to the left.
Transmission Control
1. Move the transmission control switches through all of the possible combinations. Ensure that
the proper transmission indicator lamp is on.
2. Depress the rimpull switch which is on the implement control lever. Use the rimpull selection
switch in order to toggle through the four reduced rimpull settings. The indicator light for the
rimpull must be on.
3. Depress the lockup clutch switch. The indicator lamp must turn on. When the brake pedal is
applied, the indicator lamp must turn off.
4. Depress the quickshift switch. The indicator lamp must turn on.
Parking Brake Control
1. Pull the parking brake knob outward in order to engage the parking brake. The parking brake
knob is red and the knob is located on the dash.
2. Engage the parking brake.
Select a gear with the transmission control switches. The transmission should not engage.
Return the transmission to NEUTRAL and select a gear again. The transmission should
engage and the alarm should sound intermittently. Make sure that the proper indicator lamp
comes on for the gear that is selected.
3. Push the parking brake knob inward in order to release the parking brake. If the parking brake
knob does not stay down, the system pressure of the machine is not high enough to disengage
the parking brake. Do not move the machine until the problem is corrected.
Throttle Control
1. Depress the accelerator pedal for 33 degrees when the engine is running. The pedal should be
at the mechanical stop at the bottom side of the pedal. The engine must be running at high idle
speed.
2. Release the pedal. The pedal must automatically return to the low idle position.
3. Push the throttle lock switch to the ON position. The throttle lock switch is located on the
dash.
4. Depress the throttle control in order to achieve the desired engine rpm.
5. Depress the "Set/Decal" Button in order to set the throttle. The "Set/Decal" Button is located
to the right of the implement controls.
a. Press the right brake pedal in order to disengage the throttle lock.
b. Depress the "Resume/Accel" Button in order to resume the throttle setting. The
"Resume/Accel" Button is located to the right of the implement controls.
Brake Pedals
1. Depressing the right brake pedal must apply brakes at all four wheels.
2. Depressing the right brake pedal must cause the brake lights at the rear of the machine to turn
on.
Left Pedal Control
1. Partially depressing the left pedal must allow the impeller clutch to slip. This will reduce the
output torque of the torque. The torque should be approximately 25% of the output torque
when the lockup clutch is enabled.
2. Depress the left pedal further. The machine will respond according to the next steps.
a. Apply the brakes at all four wheels.
b. The brake lights at the rear of the machine will illuminate.
Seat Controls
Check the following adjustments:
z Seat travel: 150 mm (5.9 inch) total
z Seat height: 75 mm (3 inch) total
z Seat suspension: adjustable
z The seat cushion is adjustable: two positions
z The back seat cushion is adjustable: three positions
Seat Belt
1. Adjust the seat belt to the proper length.
2. Latch the seat belt across the operator's lap. The length of the seat belt must not change. The
seat belt must not slip on the operator.
3. Release the seat belt. The seat belt must unlatch.
Hydraulic Controls for Attachment or Bucket
1. Pull the lift lever rearward to the LIFT DETENT position. The lift lever must kick out of the
LIFT DETENT position when the lift arms reach the top of travel. The lift lever must return to
the HOLD position.
Note: The magnet assembly for the lift kickout is on the right lift arm. The magnet assembly
should have been adjusted earlier in order to activate the kickout switch just below the highest
point in the lifting cycle.
2. Push the tilt lever forward in order to dump the bucket.
3. Pull the tilt lever rearward to the TILT BACK DETENT position. The tilt lever must kick out
of TILT BACK DETENT position when the bucket reaches a level position. The tilt lever
must return to the HOLD position.
4. Push the lift lever forward to the FLOAT DETENT position. The lift arms must float to the
bucket on the ground position. The lift lever must not kick out of the FLOAT DETENT
position. The lift lever must be pulled out of the detent position by hand and the lever returned
to the HOLD position.
Note: The bucket should return to the level position. If the bucket does not return to the
correct position, adjust the leveler on the tilt cylinder and repeat Step 5.a.
Instrument Panel
1. Turn the engine start switch key to the ON position. This will supply power to all of the
electrical circuits in the cab. Some functions can be checked with the key in the ON position
such as the dome lights and the windshield wipers.
2. Turn the engine start switch key to the START position. The diesel engine will start. Release
the engine start switch key after the engine starts. The engine start switch key must return to
the ON position.
3. Press the EMS, the ether aid, and the engine overspeed test switches. Check all of the indicator
lights for the monitoring system. Check the EMS warning lights. Check the action alarm.
4. Turn the engine start switch key to the OFF position. The engine must stop. The electrical
circuits in the cab must go to the de-energized state. The following components should have
electrical power:
{ instrument Panel Lights
{ Running Lights on the Front of the Machine
{ Tail Lights
{ Flood Lamps for the Access Ladder.
Climate Control
1. Cab Pressurization
With the engine stopped, turn the start switch key to the ON position. Turn the blower fan
switch to the LOW position. Then, turn the blower fan switch to the HIGH position. A normal
sound must be heard at both fan speeds.
2. Heating
The engine must be running at normal operating temperature and the valves for the heater lines
must be open. Turn the heater control switch to the ON position. Check for warm air.
3. Air Flow
Turn the blower fan switch to the LOW position or the HIGH position. There must be air flow
at the dash assembly under the front windshield. There must be air flow on both sides of the
seat support.
Windshield Wipers
1. The ignition switch must be in the ON position. Turn the wiper switches to the LOW position
and the HIGH position. The wiper arms for both the front and the rear must operate in both
modes.
2. Depress the wiper switch knobs in order to operate the washers.
3. Turn the switches to the OFF position. The wiper arms for both the front and the rear must
return to the proper OFF position.
Running Lights
1. The ignition switch must be in the OFF position. Push the three-position switch to the middle
position. The instrument panel lights and the tail lights must be ON.
2. Push the three-position switch to the UP position. The running lights must also turn ON.
Flood Lamps
The ignition switch must be in the ON position. Push the switch for the flood lamps to the ON
position. Check the flood lamps. The flood lamps must turn ON.
Auxiliary Flood Lamps
1. The ignition switch must be in the OFF position. Push the switch for the lamps at the access
ladders to the ON position. The lamps in the engine compartment must turn ON.
2. Push the switch to the ON position for the lamps in the engine compartment. The switch is
located at the ground level in the bumper assembly. The lamps in the engine compartment
must turn ON.
Dome Lights
The ignition switch must be in the OFF position. Depress the dome light switch. The dome light
must turn ON.
Lighter
The ignition switch must be in the ON position. Depress the lighter to the detent position. The lighter
must pop out of the detent position when the lighter is ready for use.
Machine Horns
The ignition switch must be in the OFF position. Press the horn switch on the floor. The horns must
sound.
Machine Operation
1. Operate the machine for a minimum of 15 minutes. Operate the machine in all gears and steer
the machine at the same time. The operation must also include simultaneous operation of the
implement system, the steering system, and the braking system.
2. Any indication of improper operation must be corrected. Improper operation can include harsh
braking, jerky steering, unusual noises, or improper linkage movements.
Final Testing of Wheel Loader
Check the complete machine. There should be no unusual noises or oil leaks. All of the quality
requirements must be fulfilled. Machine function and appearance must meet specifications. All
variances must be recorded, and the variances must be corrected.
Perform Payload Calibration
Note: A calibration weight is needed in order to properly calibrate the payload monitoring system.
Refer to Systems Operation, RENR2517, "Large Wheel Loader VIMS Payload Users Manual" for
more information.
The next steps utilize the VIMS Onboard System.
1. Select MENU.
2. Select 5: "Calibrate Payload".
3. Select 5: "Start New Calibration".
4. Follow the instructions that are given.
Note: The Weight Range must be properly set in order to generate accurate payload data. Refer to
Systems Operation, RENR2517, "Large Wheel Loader VIMS Payload Users Manual" for more
information.
Download the VIMS and ET data. Reset all of the VIMS and ET data after the machine is certified.
Checks Before Delivery of 994D Wheel Loader

The following list shows the recommended assembly checks and the system checks for the machine.
Perform the checks before the machine is delivered to the customer. Please do all the checks and
verify that all the systems function properly.
Refer to the Service Manual and the Operation and Maintenance Manual in order to correct any
system malfunction. Any system malfunction must be corrected before the machine is delivered.
After the checklist is complete, please sign your name and the name of the dealer.
Please make copies, and mail to the address provided.
Caterpillar, Inc.
Attention: LMP Product Support
994D Wheel Loader
MSC-A17
P.O. Box #504
Joliet, IL 60434-0504
Dealer____________________
Customer____________________
Product Identification Number____________________
1. Check to make sure that all of the hydraulic systems are full and the implement pump case
drains are full prior to starting the engine.YES_____ NO_____
2. Check the system pressure settings for the correct specifications.
{ Implement YES_____ NO_____
{ Pilot system YES_____ NO_____
{ Brake YES_____ NO_____
{ Steering YES_____ NO_____
{ Transmission YES_____ NO_____
{ Torque Converter YES_____ NO_____
3. Were the machine lights checked?
{ Operational YES_____ NO_____
{ Ladder light YES_____ NO_____
{ Cab YES_____ NO_____
{ Dash YES_____ NO_____
{ Engine compartment YES_____ NO_____
4. Cab:
{ Cab door opens and closes from the inside of the cab? YES_____ NO_____
{ Is the Operation and Maintenance Manual in the literature pouch? The literature pouch
is located on the back side of the operator's seat. YES_____ NO_____
{ Does the horn function correctly? YES_____ NO_____
{ Does the windshield wiper/washer function correctly? YES_____ NO_____
{ Do the seat belts function correctly? YES_____ NO_____
{ Does the fan switch function correctly? YES_____ NO_____
{ Does the heater function correctly? YES_____ NO_____
{ Does the air conditioner function correctly? YES_____ NO_____
{ Check the EMS or VIMS test. Does the check light function correctly? YES_____
NO_____
{ Does the hour meter function correctly? YES_____ NO_____
{ Check the implement functions. Lift - Raise/Lower YES_____ NO_____ Tilt -

Raise/Lower YES_____ NO_____
{ Does the automatic engine speed control function correctly? YES_____ NO_____
{ Does the steering column function correctly? YES_____ NO_____
{ Does the parking brake function correctly? YES_____ NO_____
5. Was the automatic ether injection system checked? Refer to Operation and Maintenance
Manual, SEBU7145, "994D Wheel Loader" for the correct procedure. YES_____ NO_____
6. Were all the fluid levels rechecked? YES_____ NO_____
7. Were any unusual noises or leaks corrected? YES_____ NO_____
8. Were all the lubrication hose assemblies filled with grease before installation? YES_____
NO_____
9. Is the auto lube system functioning correctly? YES_____ NO_____
10. Were all of the quality requirements fulfilled? Were all variances corrected prior to releasing
the machine to the customer? YES_____ NO_____
11. Was the back up alarm function checked? YES_____ NO_____
12. Is the machine repainted to factory satisfaction? YES_____ NO_____
13. Was there any damage during shipment? YES_____ NO_____
14. Were there any parts short from the factory? YES_____ NO_____
15. Name of the person making the checks:
{ Hydraulic____________________
{ Electrical____________________
{ Structural____________________
{ Other____________________
16. Comments:
a.____________________
b.____________________
c.____________________
d.____________________
e.____________________
f.____________________
g.____________________
h.____________________
i.____________________
j.____________________
k.____________________
l.____________________
m.____________________
n.____________________
o.____________________
p.____________________
q.____________________
r.____________________
s.____________________
t.____________________
Table 55
Specifications
Actual Comment
Description Condition Specification
Power Train
Engine RPM High Idle 1700 ± 50 rpm
Engine RPM Low Idle 750 ± 30 rpm
minimum of
Boost Pressure Torque Converter Stall 104 kPa (15 psi)
maximum of
142 kPa (21 psi)
minimum of
Oil Pressure Low Idle
138 kPa (20 psi)
minimum of
Oil pressure Full Load
276 kPa (40 psi)
1000 rpm and Full Load

Fuel Pressure 415 kPa (60 psi) to
450 kPa (65 psi)
Torque Converter
Torque Converter Stall
Engine Rpm minimum of 1510 rpm
Torque
Converter Outlet -
413 kPa (60 psi)
Torque
Converter
Lockup Clutch - 2205 ± 69 kPa (320 ± 10 psi)
Torque
Converter
- 1964 ± 103 kPa (285 ± 15
Impeller Clutch
psi)
Torque
Converter Inlet -
1619 kPa (235 psi)
Pressure
Transmission
P1 Speed Clutch
High Idle 2650 ± 140 kPa (385 ± 20
Pressure
psi)
P2 Direction
Clutch Pressure High Idle 2170 ± 105 kPa (315 ± 15
psi)
Transmission
Lubrication High Idle
140 kPa (20 psi)
Pressure
Transmission
Lubrication Low Idle
7 kPa (1 psi)
Pressure
P1-P2
Differential High Idle
380 ± 35 kPa (55 ± 5 psi)
Pressure
Torque converter output
Partially depress the left
should be 25% of the torque
pedal.
at the lockup clutch.
Shift the transmission. The transmission shifts
smoothly in all gears.
Differential and Final Drive

Brake System The pressure is below The alert indicator for the
Pressure 6900 kPa (1000 psi). parking brake must be red.
The alarm on the instrument
With the parking brake
panel must sound
engaged, shift the
intermittently and the
transmission to any gear
respective gear indicator must
except neutral.
turn on.
Brake System
Engage the parking The alert indicator for the
Pressure in the
brake. parking brake must be red.
normal range
Brake System
Pressure at
High Idle 8620 ± 350 kPa (1250 ± 50
maximum brake
psi)
pedal travel
Air System
Cut in pressure
655 kPa (95 psi)
Cut out pressure

828 ± 34 kPa (120 ± 5 psi)
Tires
Use the recommendations of
Tire pressure
the manufacturer.
Hydraulics
Standby pressure for the
Steering System
primary steering pump 3755 ± 1240 kPa (545 ± 180
psi)
Turning time between
the left turn stop and the 4.1 to 4.5 seconds
right turn stop
Difference between
steering left and 0.3 seconds max
steering right
Gap between the stops
of the frame at a full left
turn or a full right turn 100 mm (4 inch)
Articulate the machine

for three degrees and
measure the amount of
travel after stopping the
STIC movement.
Pilot Pressure Low idle 2400 ± 40 kPa (348 ± 6 psi)
High idle
Bucket at full tilt
Implement 30400 ± 500 kPa (4400 ± 73
Main relief pressure for
psi)
the implement system
Implement oil
temperature 52 °C (125 °F)
High idle
Transmission in neutral
Measure the time that is

required to raise the
empty bucket from the 12 to 13 seconds
ground to the end of the
lift cycle.
High idle
Raise the bucket until
the lift cylinders are
fully extended.
Measure the time that is 3.6 to 4.5 seconds
required to move the
bucket to the dump stop
from the full tilt back
position.
fully extended. 20 mm (.79 inch) max in 5
Measure the lift minutes
cylinder rod drift.
fully extended and the
25 mm (.98 inch) max in 5
bucket is level.
minutes
Measure the tilt cylinder
rod drift.
Accumulator Accumulator precharge

5600 ± 500 kPa (813 ± 73
Precharge
psi)
Charging Pump
Accumulator pressure at
for the Brake 15500 to 16500 kPa (2248 to
low idle
Accumulator 2392 psi)
Leakage None
Operator's Module
Steering Control Move the STIC to the The machine must articulate
right. to the right.
Move the STIC to the The machine must articulate
left. to the left.
Move the transmission
The respective indicator lamp
Transmission control switch through
for each gear must come on.
Control all of the different gear
positions.
Depress the rimpull

selection switch and The indicator lamp for the
toggle the switch rimpull must be on.
through the four
positions.
Depress the lockup The indicator lamp must turn
clutch switch. on.
Engage the parking
The VIMS parameter 314
Parking Brake brake by pulling the
must read "PARKBRK ON".
Control brake knob. View the
VIMS parameter 314.
With the parking brake
ON, select a gear with The transmission must not
the transmission switch. engage.
The transmission must

Return the transmission
engage and the alarm must
switch to NEUTRAL,
sound intermittently. The
and select the gear
respective indicator lamp
again.
must turn on.
Push the red brake knob
The knob must stay down.
downward.
The engine must be
running. Push the
Throttle Control The throttle lock lamp must
throttle lock enable
turn on.
switch to the ON
position.
Enable the throttle lock.
Depress the accelerator The engine must be running
pedal all the way to the at high idle.
stop.
The pedal must automatically
Release the accelerator
return to the low idle
pedal.
position.
Depress the accelerator
pedal and press the
The engine speed must be
throttle lock enable
held at the same rpm.
switch. Release the
accelerator pedal.
The engine speed must
be held by the throttle
The engine speed must return
lock and the accelerator
to low idle.
pedal must be released.
Press the brake pedal.
The engine speed must
Press the resume switch increase, and the engine
for the throttle. speed must return to the
previously set rpm.
This will apply the brakes to

Depress the brake pedal. all four wheels. The brake
Brake Pedal
lights at the rear of the
machine must turn on.
This will reduce the output
torque of the torque
Left Pedal Partially depress the left
converter. The torque should
Control brake pedal.
be approximately 25% of the
lockup torque converter.
This will apply the brakes to
Fully depress the left all four wheels. The brake
brake pedal. lights at the rear of the
machine must turn on.
Seat Adjustment
Travel
Lever 150 mm (5.9 inch)
Height
75 mm (3 inch)
Suspension Adjustable
Back Cushion Three positions
Adjust the seat belt to The seat belt must not slip
Seat Belt the proper length. and the seat belt must not
Fasten the seat belt. change length.
Release the seat belt. The seat belt must unlatch.
The lift lever must kick out of
the DETENT position and the
Pull the lift lever
Implement lift lever must return to the
rearward to the lift
Controls NEUTRAL position when the
DETENT position.
lift arms reach the end of
travel.
The tilt lever must kick out of
Place the bucket in the
the DETENT position and the
DUMP position. Pull
tilt lever must return to the
the tilt lever rearward to
HOLD position when the
the tiltback DETENT
bucket reaches the final
position.
position.
Push the lift lever
forward into the
FLOAT position.
VIMS does a self test. The
Instrument Turn the key to the ON
gauges will travel through the
Panel position.
entire range of motion.
Turn the ignition switch The diesel engine must start.

and hold the switch in
the START position.

Release the ignition
The key must return to the
switch after the engine
ON position.
starts.
The engine must stop. All the
electrical circuits must de-
energize except the
Turn the ignition switch
instrument panel lights, the
to the OFF position.
running lights, the tail lights,
and the lights for the access
ladders.
The engine must be
stopped and the ignition
switch must be ON.
Climate Control The fan must be audible at
Turn the fan control
both speeds.
switch to the LOW
position and the HIGH
position.
The engine must be
running at normal There must be warm air at the
operating temperature dash assembly under the front
and the valves for the windshield. There must be
heater lines must be warm air on both sides of the
open. Turn the heater seat support.
control switch ON.
There must be air flow at the
Turn the fan control
dash assembly under the front
switch to the LOW
windshield. There must be air
position or the HIGH
flow on both sides of the seat
position.
support.
The ignition switch
must be in the ON
The wiper arms for both the
Windshield position. Turn the wiper
front and the rear must
Wipers switches to the LOW
operate in both modes.
position and the HIGH
position.
Depress the wiper
The washers must operate.
switch knobs.
The wiper arms for both the
Turn the switches to the
front and the rear must return
OFF position.
to the proper OFF position.
The ignition switch
must be in the OFF The instrument panel lights
Running Lights
position. Push the three- and the tail lights must be
position switch to the ON.
middle position.
Push the three-position

The running lights must also
switch to the UP
turn ON.
position.
The ignition switch
must be in the ON
position. Push the All of the flood lamps must
Flood Lamps
switch for the flood be ON.
lamps to the ON
position.
The ignition switch
must be in the OFF
The lamps in the engine
Auxiliary Flood position. Push the
compartment must turn ON.
Lamps switch for the lamps at
the access ladders to the
ON position.
Push the switch to the
ON position for the
lamps in the engine The lamps for the engine
compartment. The compartment must turn ON.
switch is located at the
ground level in the
bumper assembly.
The ignition switch
must be in the OFF The dome light must turn
Dome Lights
position. Depress the ON.
dome light switch.
The ignition switch
must be in the ON The lighter must pop out of
Lighter position. Depress the the detent position when the
lighter to the detent lighter is ready for use.
position.
The ignition switch
Machine Horns must be in the OFF
The horns must sound.
position. Press the horn
switch on the floor.
Copyright 1993 - 2006 Caterpillar Inc. Sat Dec 16 12:53:28 UTC-0400 2006
Todos los derechos reservados.
Red privada para licenciados del SIS.

Armado 994d Inglés

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Armado 994d Inglés

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994D WHEEL LOADER 3TZ00001-00336 (MACHINE) POWERED BY 3516B E...

Producto: WHEEL LOADER

994D Wheel Loader Assembly Procedure{7000}

Personal injury or death can result from improper assembly

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Clean all of the surfaces before you install any parts.

Prepare the Site

Identify the Parts and Organize the Parts

Next Level Part

Hand Rail on the Rear Fender

8X-1740 Fixed Axle Fastener Group Front Axle

Hand Rail on the Rear Fender

Dimensions and Weights of Components

Personal injury or death can result from lifting a heavy assembly.

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Dimensions And Weights

Tire (49.5 x 57)

Rim 1755 kg (3869 1753 mm (69 1219 mm (48 1753 mm (69

Requirements for the Crane

Centerline to side of Engine End Frame

Centerline to side of Non-Engine End Frame

Centerline to the edge of the axle without the tires

Ground level to the top of the ROPS

Width of the machine and the bucket

Ground level to the top of the Non-Engine End Frame (2)

Minimum spreader bar width

Equipment for Assembly

z Two cranes with an individual capacity of 68100 kg (150135 lb)

z A lift truck with a capacity of 6810 kg (15000 lb)

z Nitrogen Charging Equipment

z 110 Volt Generator

z One 1.8 m (6 ft) ladder and one 2.4 m (8 ft) ladder

z Blocking for the Engine End Frame

z Blocking for the Non-Engine End Frame

z 5P-0306 Vacuum Transducer

z 3D-2824 O-Ring Seal

z Paint Remover or Cleaning Solvent

z Lifting Beams, Lifting Slings, Chains, Cables, Shackles and Hooks.

Tooling for Assembly

Hand Tools that are Required for Assembly

z 1U-7820 Wrench Set

z 8T-5183 Drive Extension

z The following sockets will be required for assembly.

Thread Size (mm) Socket Size (mm) Part Number Description

Part Number Description

Tooling that is Required for Setting Torque

z 6V-7820 Torque Multiplier Gp Capacity of 1630 N·m (1200 lb ft)

z 6V-6080 Torque Multiplier Gp Capacity of 4335 N·m (3200 lb ft)

z 8T-5230 Torque Wrench

z 4C-9814 Reaction Bar

z Special Instruction, SEHS7150

z The following torque wrench adapters will be required for assembly.

Socket Size (mm) Part Number

Guide Bolts that are Required for Assembly

Diameter (mm) Part Number Length

Jacks that are Required for Assembly

z 80.8 metric ton (79.5 ton) jack stand gp

z The following lifting brackets will be required for assembly.

Part Number Size (mm) Capacity (1)

z The following link brackets will be required for assembly.

Part Number Capacity Opening (mm)

4086 kg (9000 lb) 20 mm (0.8 inch)