Media Search - M0072093 - Supplemental Cooler Rework Procedure For Certain 994F Wheel Loaders (1374)

14/5/2020 Media Search - M0072093 - Supplemental Cooler Rework Procedure for Certain 994F Wheel Loaders {1374}
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Special Instruction
Supplemental Cooler Rework Procedure for Certain 994F Wheel Loaders {1374}
Media Number -M0072093-01 Publication Date -09/09/2019 Date Updated -09/09/2019
i07897341
Supplemental Cooler Rework Procedure for Certain 994F Wheel

Loaders {1374}
SMCS - 1374
Wheel Loader
994F (S/N: 4421-UP)
Introduction
Table 1
Revision History
Revision Summary of Changes
01 Updated the torque converter pedal pressure in the Section "Post Build Calibrations".
This special instruction contains procedures and information to install a supplemental cooler group for a 994F
Wheel Loader.
Do not perform any procedure in this Special Instruction until you have read the information and you understand
the information.
Safety
Personal injury or death can result from fumes, gases and ultraviolet
rays from the weld arc.
Welding can cause fumes, burn skin and produce ultraviolet rays.
Keep your head out of the fumes. Use ventilation, exhaust at the arc, or
both, to keep fumes and gases from your breathing area. Wear eye, ear
and body protection before working.
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Protect yourself and others; read and understand this warning. Fumes
and gases can be dangerous to your health. Ultraviolet rays from the
weld arc can injure eyes and burn skin. Electric shock can cause death.
Read and understand the manufacturer's instructions and your

employer's safety practices. Do not touch live electrical parts.
See "American National Standard Z49.1, Safety in Welding and

Cutting" published by the American Welding Society.
American Welding Society

2501 N.W. 7th Street
Miami, Florida 33125
See "OSHA Safety and Health Standards, 29 CFR 1910", available from
U.S. Department of Labor.
U.S. Department of Labor

Washington, D.C. 20210
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.
Do not operate or work on this machine unless you have read and
understand the instructions and warnings in the Operation and
Maintenance Manuals. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact any Caterpillar dealer
for replacement manuals. Proper care is your responsibility.
For machines equipped with quick coupler, improper attachment of

work tools could result in injury or death.
Do not operate this machine until you have positive indication that the
coupler pins are fully engaged. Follow recommended procedure in
Operation and Maintenance Manual.
Securely fasten radio (if equipped) and all loose items such as lunch
boxes or tools. Failure to do so could allow items to shift position during
rough machine operation or tip over and result in injury. Refer to the
Operation and Maintenance Manual for specific fastening and latching

requirements.
Sudden movement or accidental starting of the machine can cause

personal injury or death to persons on or near the machine.
To prevent personal injury or death, perform the following:
Park the machine on a smooth level surface.
Lower the blade and or attachments to the ground.
Stop the engine and engage the parking brake.
Block the wheels and install the steering frame lock.
Turn the battery disconnect switch to the OFF position and remove the
key.
Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the

battery disconnect switch location to inform personnel that the machine
is being worked on.
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact skin.
At operating temperature, the engine coolant is hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the
cooling system pressure cap is cool enough to touch with your bare
hand.
Remove the cooling system pressure cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid contact with the skin
and eyes to prevent personal injury.
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using
hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine
fluids.
Engine Fluids (Oil, Fuel, and Coolant) are a threat to the environment. Properly recycle or dispose of engine
fluids according to local regulations. Never put engine fluids in the trash, on the ground , in sewers or bodies
of water.
Wear gloves and other protective gear while working with hot engine fluids. Use caution when draining hot
engine fluids and avoid direct skin contact.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This person
should also have the necessary training, skills, and tools to perform these functions properly. Safety
precautions and warnings are provided in this instruction and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate
every possible circumstance that might involve a potential hazard. Therefore, the warnings in this
publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work
method, or operating technique that is not recommended by Caterpillar is used, make sure that procedure is
safe for you and for other people to use. Make sure that the product will not be damaged or the product will
be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Required Parts
Table 2
REQUIRED PARTS
QTY PART NUMBER NAME
1 506-0726 Hydraulic Oil Cooler Ar
Welded Parts
Table 3
WELDED HARDWARE
QTY PART NUMBER NAME
2 102-8895 Plate
4 7Y-2522 Plate
6 8X-7415 Plate
3 9R-2613 Weld Boss
4 9R-2640 Boss
1 148-3072 Block
1 8X-4711 Boss As
6 8X-1690 Block
1 264-1279 Block
Machine Preparation
Illustration 1 g06205280
(A) 270 mm (10.63 inch)
(B) 574.45 mm (22.62 inch)
(C) 165.89 mm (6.53 inch)
1. Locate and install two 102-8895 Plates (1) at the dimensions shown above.
(A) 545.6 mm (21.48 inch)
(B) 1370.2 mm (53.94 inch)
(C) 910.5 mm (35.85 inch)
(D) 40 mm (1.57 inch)
(E) 300 mm (11.81 inch)
(F) 527.55 mm (20.77 inch)
(G) 340.9 mm (13.42 inch)
2. Locate and install four 8X-7415 Plates (2) at the dimensions shown above.
(A) 40 mm (1.57 inch)
(B) 105.6 mm (4.16 inch)
(C) 958.2 mm (37.72 inch)
(D) 918.2 mm (36.15 inch)
3. Locate and install two 9R-2613 Weld Bosses (3) at the dimensions shown above.
(A) 150.6 mm (5.93 inch)
(B) 1005.5 mm (39.59 inch)
(C) 1206 mm (47.48 inch)
(D) 1005.5 mm (39.59 inch)
(E) 50 mm (1.97 inch)
(F) 629 mm (24.76 inch)
(G) 691 mm (27.20 inch)
(H) 1355.2 mm (53.35 inch)
4. Locate and install four 9R-2640 Bosses (4) at the dimensions shown above.
(A) 242 mm (9.53 inch)
(B) 65.5 mm (2.58 inch)
(C) 835 mm (32.87 inch)
(D) 152.5 mm (6 inch)
5. Locate and install two 7Y-2522 Plates (5) at the dimensions shown above.
(A) 175 mm (6.89 inch)
(B) 815 mm (32.07 inch)
(C) 108 mm (4.25 inch)
6. Locate and install two 7Y-2522 Plates (6) at the dimensions shown above.
(A) 152 mm (5.98 inch)
(B) 74.5 mm (2.93 inch)
(C) 119.5 mm (4.70 inch)
(D) 160 mm (6.30 inch)
7. Locate and install two 8X-7415 Plates (7) at the dimensions shown above.
(A) 353.85 mm (13.93 inch)
(B) 83.4 mm (3.28 inch)
8. Locate clip (8) using the dimensions above.
Add a 13.5 mm (0.53 inch) clearance hole to the RH side of 304-0419 Cover As (8A).
(A) 44 mm (1.73228 inch)
(B) 215 mm (8.46455 inch)
(C) 265 mm (10.43305 inch)
(D) 309 mm (12.16533 inch) to center
(E) 183 mm (7.20471 inch) to center
(F) 214 mm (8.42518 inch) to center
9. Measure along the rail from the saddle and drop vertical down at the dimensions shown to locate hardware.
Note: The ground boss (10) must be free of all paint.
9R-2613 Weld Boss (9) at (A) over, and (D) down to center.
8X-4711 Boss As (10) at (B) over, and (E) down to center.
148-3072 Block (11) at (C) over, and (F) down to front corner.
10. To gain access, remove the RH stairs (12), handrail (13), and mud flaps (14). Retain removed parts for
reinstallation. Refer to Special Instruction REHS4997. Refer to Step 11 for an alternate process.
Note: Do not remove tire.
11. Instead of removing the RH stairs, handrail, and mud flaps, an alternate process is to modify the tread plate
(15). Cut the tread plate shown above and slide out from underneath stairs.
Note: Due to the increased risk of fire remove the top panel above the fuel tank. Clean all debris from
around the fuel tank prior to rework. The stairs will need to be removed to access the top panel.
12. Remove top panel (16) above fuel tank. Clean around fuel tank before proceeding.
(A) 87.50 mm (3.44 inch)
(B) 100 mm (3.94 inch)
(C) 90 mm (3.54 inch)
13. Cut a clearance notch in the existing plate to allow hose routing. Round all internal corners to remove sharp
edges up to 20 mm (0.7 inch).
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(A) 115 mm (4.53 inch)
(B) 141 mm (5.55 inch)
14. Remove 101-3329 Panel (17), 5P-7482 Seal (18), and all associated hardware. Retain for reinstallation.
15. Use dimensions (A) and (B) to cut a notch in 101-3329 Panel (17) to allow hose routing. Trim 5P-7482 Seal,
as necessary. To prevent hose damage, round internal corners up to 10 mm (0.39 inch).
(A) 100 mm (3.94 inch)
(B) 103 mm (4.06 inch)
(C) 22 mm (0.87 inch)
(D) 330 mm (12.99 inch)
16. Use dimensions above to cut a clearance hole in 251-2200 Plate (19) to allow hose routing. To prevent hose
damage, round internal corners up to 10 mm (0.39 inch).
17. Refer to 1E0279A English and 1E0279B Metric torque specifications above.
Refer to Illustration 16 for torque tightening sequence:
a. Apply 100% torque to bolts numbered 1/5 and 2/6.
b. Apply 100% torque to bolts numbered 3 and 4.
c. Reapply 100% torque to bolts numbered 1/5 and 2/6.
18. Use the following sequence to apply incremental tightening assembly torques.
a. Apply 80% of specified torque to bolts numbered 1/5 and 2/6.
b. Apply 80% of specified torque to bolts numbered 3/7 and 4/8.
c. Apply 100% of specified torque to bolts numbered 1/5 and 2/6.
d. Apply 100% of specified torque to bolts numbered 3/7 and 4/8.
19. Remove the following hardware from the handrail connector:
Two 8T-4244 Nuts (20)
Two 8T-4223 Hard Washers (21)
Two 5P-1076 Hard Washers (22)
Two 8T-4183 Bolts (23)
Two 6V-1874 Grommets (24)
Two 5P-7469 Clips (25)
One 115-3580 Plate (26)
Two 5P-7468 Clips (27)
20. Remove eight 8T-4196 Bolts (28), eight 8T-4121 Hard Washers (29), two 8T-4136 Bolts (30), and two 8T-
4121 Hard Washers (29) from the 7I-5024 Handrail As (31).
21. Remove the 7I-5024 Handrail As (31).
22. Torque 5D-1026 Band Clamp to 7.5 ± 1 N·m (66.38062 ± 9 lb in).
23. Remove the following parts from the 365-3631 Guard Plate (32):
Four 8T-4192 Bolts (33)
Four 5P-1076 Hard Washers (34)
Four 5C-7261 Nuts (35)
Four 8T-4224 Hard Washers (36)
Two 248-0102 U-Bolts (37)
(A) 100 mm (3.94 inch)
(B) 375 mm (14.76 inch)
(C) 100 mm (3.94 inch)
(D) 450 mm (17.72 inch)
(E) 56.23 mm (2.21 inch)
24. Use the dimensions above to cut clearance notches on the 283-1553 Tread (38).
25. Remove 8X-3178 Plate (39).
26. Remove four 8T-4137 Bolts (40), four 8T-4136 Bolts (41), eight 7X-7729 Washers (42), eight 112-6673
Clips (43) from 272-1148 Grill As (44).
27. Remove the 272-1148 Grill As (44).
28. Use fourteen 8T-4193 Bolts (45) and 198-4780 Hard Washers (46) to attach one 264-1279 Block (47) and
six 8X-1690 Blocks (48) to 511-6656 Plate As (49).
Low torque all bolts to 125 ± 20 N·m (90 ± 15 lb ft).
29. Install 296-8187 Bolt (50) on the 511-6656 Plate As (49) after installation.
Note: To achieve an accurate vertical position of the coolers, make sure that the tread plate has been
installed on bumper.
30. Attach Hoist Rings to either hole (A) of the 511-6656 Plate As (49). The weight of the plate assembly is
150 kg (330 lb).
31. Position the 511-6656 Plate As (49) onto bumper surface.
32. Make sure that the 511-6656 Plate As (49) is level. Adjust the 296-8187 Bolt (50) if necessary.
33. Locate the previously installed blocks to the bumper.
34. Tack weld all blocks onto the bumper.
35. Remove bolts holding blocks onto the 511-6656 Plate As (49).
36. Remove 511-6656 Plate As (49) and prepare marked locations for welding.
Note: Fuel tanks are located inside the bumper. Take proper precaution when welding in the area.
37. Use 8 mm (0.31 inch) fillet welds on both vertical faces of blocks.
38. Weld block on top of bumper with an 8 mm (0.31 inch) fillet weld from (A) to (B).
Note: Assemble the cooler support assembly on the ground. After assembly, the whole package will be set
onto the bumper. The sub assembly work can be completed off-site before installation to limit machine
downtime.
39. Assemble the following parts to the 511-6656 Plate As (49):
One 511-6669 Plate As (52)
One 511-6661 Plate As (53)
One 511-6664 Tube (54)

One 511-6660 Post As (55)
One 511-6658 Post As (56)
One 511-6663 Tube As (57)
40. Use four 8T-4183 Bolts (58), four 8T-4194 Bolts (59), and eight 8T-4223 Hard Washers (60) to fasten the
plate and post assemblies.
41. Install two 223-7064 Spacers (61), six 8T-4223 Hard Washers (62), two 141-6518 Spacers (63), and six 8T-
4194 Bolts (64)
42. Install two 223-7064 Spacers (65), ten 8T-4223 Hard Washers (66), two 141-6518 Spacers (67), and ten 8T-
4194 Bolts (68), and one 8T-4183 Bolt (69).
43. Attach a suitable lifting device to weld nut location (70).
44. Align 1A-2610 Dowel (71) with dowel hole on subassembly and position subassembly onto the base plate.
45. Secure assembly with eight 198-4780 Hard Washers (72) and eight 8T-4140 Bolts (73) to the base.
46. Remove four fan guard bolts (74) and discard.
47. Install four 7X-0613 Hard Washers (75) and four 8T-4908 Bolts (76) to secure the fan guard. The 7X-0613
Hard Washers will provide more axial clearance for the fan.
48. Attach a suitable lifting device to the 419-9804 Axle Oil Cooler Gp (77).
49. Position the 419-9804 Axle Oil Cooler Gp (77) onto the 511-6658 Post As (78).
50. Use eight 5R-5927 Washers (79), four 114-4426 (80), and four 172-9966 Bolts (81) to secure the 419-9804
Axle Oil Cooler Gp (77).
51. Use four 8T-4821 Washers (82), four 8T-4192 Bolts (83), and four 5C-8815 Washers (84) to assemble the
511-6667 Guard As (85).
52. Assemble 480-3232 Hose As (98) and 480-3233 Hose As (96) using the following:
Four 173-1437 Half Flange (86)
Eight 8T-4183 Bolts (87)
Eight 8T-4223 Hard Washers (88)
Two 4J-0522 O-Ring Seals (89)
53. Attach 480-3232 Hose As (98) using the following:
One 198-4788 Support As (90)
One 8T-4223 Hard Washer (91)
One 8T-4194 Bolt (92)
One 5P-7468 Clip (93)
One 5P-7469 Clip (94)
One 5P-8444 Grommet (95)
54. Route the 480-3233 Hose As (96) close to support 511-6660 Post As (97) as shown above.
55. The 480-3232 Hose As (98) routes to clipping point in the center of 511-6660 Post As (97)
56. Attach a suitable lifting device to the 419-9804 Axle Oil Cooler Gp (99).
57. Position the 419-9804 Axle Oil Cooler Gp (99) onto the 511-6658 Post As (100).
58. Use eight 5R-5927 Washers (101), four 114-4426 (102), and four 172-9966 Bolts (103) to secure the 419-
9804 Axle Oil Cooler Gp (99).
59. Use four 8T-4821 Washers (104), four 8T-4192 Bolts (105), and four 5C-8815 Washers (106) to assemble
the 511-6667 Guard As (107).
60. Use five 5C-8815 Washers (108), Five 8T-4821 Washers (109), four 8T-4183 Bolts (110), and one 8T-4192
Bolts (111) to fasten to the support.
61. Install the following parts onto the 419-9804 Axle Oil Cooler Gp (99):
Two 480-3249 Tube As (112)
One 480-3251 Hose As (113)
One 480-3252 Tube As (114)
Two 148-8316 Connector As (115)
One 148-8322 Connector As (116)
Two 148-8430 Tee As (118)
One 153-6260 Tee As (120)
One 6V-9746 O-Ring Seal (121)
One 8T-1889 Clip (122)
One 8T-1890 Clip (123)

One 8T-4196 Bolt (126)
62. Install two 225-4131 Film (127) and one 224-6820 Film (128).
63. Use a suitable lifting device to lift the entire assembly onto the machine. Use lifting points (129).
Note: The assembled 419-9804 Axle Oil Cooler Gp weighs 440 kg (970 lb).
64. Use fourteen 8T-4193 Bolts (130) and fourteen 198-4780 Hard Washers (131) to fasten the cooler assembly
to the machine.
65. Remove existing 263-5064 Piston Pump Gp cover and bolts and discard.
66. Install one 141-2447 Hydraulic Pump Mounting Gp (131) onto the 263-5064 Piston Pump Gp.
67. Use two 8T-4139 Bolts (132) and two 5P-1076 Hard Washers (133) to install 510-8341 Piston Pump Gp
(134).
68. Remove existing 289-9212 Hose As and 289-9213 Hose As.
69. Install the following components:
One 480-3220 Plate As (135)
One 480-3221 Hose As (136)
One 480-3222 Hose As (137)
Four 4J-0527 O-Ring Seals (138)
Eight 1P-4582 Half Flange (139)
Two 6V-1867 Clips (140)
Two 6V-1868 Clips (141)
Eighteen 8T-4223 Hard Washers (143)
One 9X-8257 Washer (144)
One 8T-4139 Bolt (145)
Sixteen 8T-4183 Bolts (146)
One 8T-4779 Bolt (147)
One 8T-4956 Bolt (148)
Four 204-2281 Cable Straps (149)
Two 200-6345 Mounts (150)
70. Remove existing 8X-2996 Elbow and discard all related hardware.
Note: Before installation of new bolts, use a bottoming die into the pump. The bottoming die will increase
thread engagement of the new bolts. The included hardware can be used in any combination to get
maximum thread engagement.
71. Use four 9X-8257 Washers and four 198-4780 Hard Washers (151), two 7X-2475 Bolts (152), and two 7X-
2560 Bolts (153) to install two 8T-9527 O-Ring Seals (154), one 480-3266 Manifold (155), and one 8X-
2996 Elbow (156).
72. Remove 242-3539 Hose As and discard all related hardware.
73. Use two 1H-6227 O-Ring Seals (157), four 1P-7016 Half Flange (158), eight 9X-8257 Washers (159), and
eight 8T-4193 Bolts (160) to install 480-3267 Hose As (161).
74. Install the following parts for 480-3265 Hose As (162).
One 480-3265 Hose As (163)
One 160-8708 Bracket As (164)
Four 1P-4579 Half Flange (165)
Three 8T-4183 Bolt (168)
Five 8T-4184 Bolts (169)
Note: Install adapters before placing the manifold onto the machine.
One 480-3258 Manifold (170)
One 480-3257 Hose As (171)
Two 8C-3206 Half Flange (172)
One 180-9933 Adapter As (176)
One 164-5567 Quick Disconnect Coupler As (177)
One 6V-0852 Dust Cap (178)
One 148-8369 Elbow As (179)
76. Install the following components to the previously installed weld block:
One 352-2735 Control Manifold Gp (180)
Two 198-4775 Hard Washers (181)
Two 7X-2535 Bolts (182)
One 148-8378 Elbow As (183)
One 268-1505 Tee As (185)
77. Install one 148-8369 Elbow As (186), one 480-3263 Hose As (187), and one 480-3262 Hose As (188).
78. Replace 148-8339 Connector As with 162-5709 Tee As (189).
79. Add one 148-8449 Swivel Tee (190) and reattach coupling.
80. Install two 148-8336 Connector As (191), two 148-8388 Elbow As (192), one 480-3261 Hose As (193), and
one 480-3264 Hose As (194).
Note: Align 148-8388 Elbow As (192) on pump at a 30 degree angle. See Illustration 56
81. Remove 311-7253 Hose As.
82. Discard all related hardware. Use the following components to install 480-3224 Hose As (195):
Two 1P-3705 Rectangular Seals (196)
One 121-1340 Angle As (198)
One 6V-1573 Clip (199)
One 6V-1875 Grommet (200)
One 6V-1572 Clip (201)
Eight 9X-8257 Washers (202)
Three 8T-4121 Hard Washers (203)
Two 8T-4195 Bolts (205)
One 344-5675 Nut (206)
83. Remove 311-7252 Hose As.
84. Discard all related hardware. Use the following components to install 480-3223 Hose As (207):
Three 5P-7463 Clips (208)
Three 6V-0683 Grommets (209)
Three 5P-7462 Clips (210)

One 7X-7729 Washer (212)
Two 8T-4183 Bolts (213)
One 8T-4195 Bolt (214)
Four 204-2281 Cable Straps (215)
Two 200-6345 Mounts (216)
85. Use two 8T-4195 Bolts (217), and two 8T-4121 Hard Washers (218) to install two 313-5299 Bracket As
(219).
86. Use four 8T-4136 Bolts (220), and four 7X-7729 Washers (221) to install 437-4821 Bracket As (222).
87. Use four 8T-4956 Bolts (223), and four 5P-1076 Washers (224) to install 480-3250 Bracket (225).
88. Use the follow hardware to install 416-8241 Sequence Valve Gp (226) and 419-0859 Hydraulic Screen Gp
(227) onto the newly installed brackets:
Note: Orient the 419-0859 Hydraulic Screen Gp housing notch with notch on bracket (A).
Two 138-5081 Flanges (228)
Two 415-8651 Flanges (229)
Two 5K-9090 O-Ring Seals (232)
Ten 7X-7729 Washers (233)
Two 7X-2543 Bolts (235)
One 480-3234 Tube As (239)
One 480-3231 Tube As (240)
One 480-3235 Tube As (241)
One 480-3230 Tube As (242)
Six 5K-9090 O-Ring Seals (243)
Six 5P-7468 Clips (244)
Six 5P-7469 Clips (245)
Six 8T-9518 Grommets (246)
Six 8T-4223 Hard Washers (247)
Six 8T-4956 Bolts (248)
1695 mm (67 inch) 324-9708 Insulation (249)
As Required 204-2281 Cable Strap (250)
As Required 200-6345 Mount (251)
One 480-3219 Tube As (252)
One 480-3256 Tube As (253)
One 480-3255 Tube As (254)
Two 164-4058 Reducer As (255)
Four 6V-8400 O-Ring Seals (256)
Eight 8K-4691 Half Clamps (257)
One 480-3226 Plate As (260)
One 480-3224 Hose As (261)
One 480-3260 Hose As (262)
Two 8T-1888 Clips (264)
Two 8T-1887 Clips (265)
Two 353-7957 Grommets (266)
Two 9P-2495 Spacers (267)
Two 8T-4198 Bolts (271)
As Required 204-2281 Cable Straps (272)
As Required 200-6345 Mount (273)
Note: For machines S/N:442283-UP use 480-3229 Hose As. Refer to the following steps.
92. Remove 148-8334 Connector As and 315-5636 Hose As. Discard all related hardware
93. Use the following components to install one 480-3228 Hose As (274):
One 494-1461 Adapter As (275)
One 148-8453 Tee As (276)
Two 5P-7470 Clips (277)
Two 5P-7471 Clips (278)
One 8T-4184 Bolts (282)
One 329-3356 Nut (283)
94. Remove existing 317-1522 Hose As and discard the related hardware.
95. Install the following hose assembly and related hardware.
One 480-3237 Plate (284)
One 6G-1444 Adapter (285)
One 480-3238 Hose As (286)
One 6V-1867 Clip (290)
One 6V-1868 Clip (291)
One 6V-1869 Grommet (292)
Nine 8T-4223 Hard Washers (293)
Four 7X-2549 Bolts (294)
One 8T-4956 Bolt (295)
96. Use the following components to install 480-3229 Hose As (297) and 480-3236 Hose As (298):
One 148-8357 Elbow As (299)
Two 204-2281 Cable Straps (301)
One 200-6345 Mount (302)
Note: For machines (S/N: 4421-282), refer to the following steps.
97. Disconnect torque converter hose (303).
98. Install 6G-1444 Adapter (304) onto existing block (305) with 538-4020 Hose As attached (306).
Note: The orifice plate location is important. Make sure that the plate is oriented properly. Connection point
moves to back LH corner. See Step 99
Hose routing for machines (S/N: 442283-UP)
Hose routing for machines (S/N: 4421-282)
(309A) 538-4021 Hose As
(310A) 480-3229 Hose As
(310B) 538-4020 Hose As Connect to torque converter outlet.
99. Use one 148-8357 Elbow As (307), one 371-7211 Connector As (308), and one 480-3236 Hose As (309).
Orient the 480-3236 Hose As (309) as shown above.
Note: For machines (S/N: 4421-282), 480-3236 Hose As will be replaced with 538-4021 Hose As. Route the
new 538-4021 Hose As toward the rear left corner.
100. Install 480-3229 Hose As (310).
101. Install the following components onto the cooling motors:
One 480-3247 Hose As (311)
One 480-3248 Hose As (312)
One 480-3253 Hose As (313)
One 148-8429 Tee As (314)
One 5P-7466 Clip (315)
One 5P-7467 Clip (316)
Four 5P-7468 Clips (317)
Four 5P-7469 Clips (318)
Four 6V-4349 Grommets (320)
Five 8T-4223 Hard Washers (321)
Two 8T-4183 Bolts (322)
Three 8T-4956 Bolts (323)
102. Remove and discard all existing hardware connecting 264-8074 Tube As.
Cut 264-8074 Tube As in half and remove.
One 480-3225 Tube As (324)
One 480-3245 Manifold (325)
One 480-3246 Hose As (326)
One 480-3244 Tube As (327)
One 148-8357 Elbow As (329)
One 148-0524 Gasket (330)
Three 4J-0524 O-Ring Seals (331)
Two 7S-8920 Clips (333)
Two 7S-8921 Clips (334)
Fourteen 8T-4223 Hard Washers (335)
Thirteen 8T-4183 Bolts (336)

One 329-3356 Nut (337)
Note: Orient the 148-8357 Elbow As (329) parallel to ground.
104. Remove 264-8080 Hose As, and 264-8081 Hose As. Discard all related hardware. Replace with 480-3239
Hose As (330) and 480-3243 Hose As (331) and the following hardware:
Two 6G-1444 Adapters (333)
Four 4J-0527 O-Ring Seals (334)
Eight 1P-4582 Half Flange (335)
Eleven 6V-1867 Clips (336)
Eleven 6V-1868 Clips (337)
Eleven 6V-1869 Grommets (338)
Two 081-6344 Spacers (339)
Twenty-Seven 8T-4223 Hard Washers (340)
Eight 7X-2549 Bolts (341)
Nine 8T-4139 Bolts (342)
Two 8T-4910 Bolts (344)
105. Use the following hardware to install the 480-3232 Hose As (345) and 480-3233 Hose As (346) onto the
bottom cooling unit:
One 480-3232 Hose As (345)
One 480-3233 Hose As (346)
One 5P-7468 Clip (349)
One 5P-7469 Clip (350)
One 198-4778 Hard Washer (352)
Nine 8T-4223 Hard Washers (353)
One 8T-4194 Bolt (355)
700 mm (28 inch) 324-9708 Insulation (356)
106. Use the following hardware to install the 480-3240 Hose As and 480-3242 Hose As onto the top cooling
unit:
One 480-3240 Hose As (357)
One 480-3242 Hose As (358)
One 480-3241 Plate (359)
Two 245-9702 Spacer Flange (360)
One 148-8357 Elbow As (362)
Two 6V-3965 Fittings (363)
Three 4J-0522 O-Ring Seals (365)
Two 4J-5573 O-Ring Seal (366)
Five 6V-1867 Clips (368)
Five 6V-1868 Clips (369)
Five 6V-1869 Grommets (370)
Thirteen 8T-4223 Hard Washers (371)
Five 8T-4910 Bolts (374)
2051 mm (81 inch) 324-9708 (375)
Two 6V-0852 Dust Caps (376)
107. Adjust the hose routing to make sure that the access door (377) swings free without obstruction.
108. Make sure the adapter (378) is fully threaded into manifold. A fully engaged adapter will allow door
clearance when opening and closing access door (377).
109. Use four 8T-4121 Hard Washers (379), three 8T-4195 Bolts (380), and one 8T-4136 Bolt (381) to install
511-6665 Guard As (382) on the top cooler.
110. Use four 8T-4121 Hard Washers (383), three 8T-4195 Bolts (384), and one 8T-4136 Bolt (385) to install
511-6665 Guard As (386) on the bottom cooler.
Note: One 8T-4195 Bolt (384) is used to assemble a two piece clip (387).
111. Make sure the 480-3269 Hydraulic Fan Lines Gp (387) and 506-9117 Axle Oil Cooler Gp (388) have been
installed, prior to assembling the guard group.
112. Use two 8T-4121 Hard Washers (389) with two 8T-4136 Bolts (390) to install 506-7629 Plate As (391).
113. Use six 8T-4121 Hard Washers (392) with six 8T-4136 Bolts (393) to install 506-7628 Plate As (394).
114. Use seven 7X-7729 Washers (395) with seven 8T-4136 Bolts (396) to install one 506-7630 Baffle (397) and
one 506-7631 Baffle (398).
115. Install 479-2926 Guardrail As (399). Use the following hardware:
Two 8T-4183 Bolts (401)
116. Use the following hardware to reinstall the handrail connector:
Two 8T-4244 Nuts (405)
Two 5P-7469 Clips (407)
Two 5P-7468 Clips (408)
One 115-3480 Plate (409)
Two 8T-4138 Bolts (410)
Two 5P-1076 Hard Washers (411)
Electrical
Harness Installation
Route the 535-8508 Harness As (1) shown above.
Refer to the following steps:
1. Use the following hardware to fasten the 535-8508 Harness As (1):
One 130-5300 Clip (2)
One 204-8000 Cable Tie Mounting (3)
One 8T-4195 Bolt (5)
One 8T-4179 Bolt (7)
As Required 204-2281 Cable Straps (8)
Note: 130-5300 Clip (2) is mounted under 204-8000 Cable Tie Mounting (3) and faces inward. Use 130-
5300 Clip (2) to secure resistor.
2. Continue routing 535-8508 Harness As (1), and attach at the next location shown above. Use the following
hardware to fasten the harness:
Two 8T-4121 Hard Washer (9)
Two 204-8000 Cable Tie Mounting (10)
Two 204-2281 Cable Straps (11)
One 8T-4195 Bolt (12)
One 8T-4136 Bolt (13)
3. Continue routing 535-8508 Harness As (1). Use 290-5562 Mount (14) with 204-2281 Cable Straps (15) to
secure.
4. Continue routing 535-8508 Harness As (1). Use two 290-5562 Mounts (16) with four 204-2281 Cable Straps
(17) to fasten the 535-8508 Harness As (1).
5. Continue routing 535-8508 Harness As (1). Use four 290-5562 Mounts (18) with eight 204-2281 Cable
Straps (19), to secure the harness along the existing lines.
6. Use 7K-1181 Cable Straps (20), as needed, to secure the harness.
7. Route the 535-8508 Harness As .up to RH side of cab. Plug pin from 535-8508 Harness As (1) into unused
location of connection in bottom corner (21). Secure with 7K-1181 Cable Strap (22).
8. Install 395-3097 Rocker Switch (23) in open port on the console. Connect 395-3097 Rocker Switch (23) to
535-8508 Harness As. Secure harness with 7K-1181 Cable Straps (24), as needed.
9. Plug pin into same corner location (25) on inside connector.
10. 395-3097 Rocker Switch (23) mounted inside cab on console.
11. Disconnect the connector (26) that is coming from the back of the key ignition switch.
12. Attach two connectors (27) on new harness to the two connectors from the key ignition switch.
13. If desired, connect two free wires (28) to power switch LED.
Specifications
Note: All additional volumes are estimated
Torque Converter/Transmission will require an extra 15 L (4 US gal).
Implement will require an extra 12 L (3 US gal).
Steering System will require an extra 8 L (2 US gal).
Refer to Operation and Maintenance Manual, "Lubricant Information", SEBU6250 for fluid types based on
ambient temperatures.
Starting Procedure
1. Prime new pump and motors with oil before starting machine.
2. Remove solenoid and valve from upper fan motor to make sure that all air is purged from upper motor.
3. Start the machine
4. Idle the machine and check for leaks.
Test and Adjust

Test the torque converter outlet pressure.
1. Warm transmission oil up to 73° C (163° F).
2. Idle engine to 1700 RPM.
3. Make sure that transmission is in Neutral.
4. Torque converter outlet pressure should be 490 ± 30 kPa (71 ± 4 psi).
Note: If the torque converter outlet pressure is not correct, the orifice plate will have to be modified. If
pressure is higher than desired, increase orifice hole diameter. If pressure is lower than desired, decrease
orifice hole diameter.
Post Build Calibrations

Perform the following calibration when the transmission oil is warmed to 75° C (167° F):
Calibrate impeller clutch pedal
Calibrate the impeller clutch solenoid
Use Cat® Electronic Technician (Cat ET) to set the minimum torque converter pedal pressure to
400 ± 100 kPa (58 ± 15 psi)
Perform the following fan speed calibration with warm steering oil and engine speed set at 1700 RPM:
Minimum fan speed: 500 ± 100 RPM
Maximum fan speed: 2850 ± 100 RPM
Note: There are expected differences in the upper and lower fan speeds.
Copyright 1993 - 2020 Caterpillar Inc. Thu May 14 2020 17:00:20 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
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Media Search - M0072093 - Supplemental Cooler Rework Procedure For Certain 994F Wheel Loaders (1374)

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Media Search - M0072093 - Supplemental Cooler Rework Procedure For Certain 994F Wheel Loaders (1374)

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14/5/2020 Media Search - M0072093 - Supplemental Cooler Rework Procedure for Certain 994F Wheel Loaders {1374}

Supplemental Cooler Rework Procedure for Certain 994F Wheel

Read and understand the manufacturer's instructions and your

See "American National Standard Z49.1, Safety in Welding and

American Welding Society

U.S. Department of Labor

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

Approximate weights of the components are shown. Clean all surfaces

For machines equipped with quick coupler, improper attachment of

Operation and Maintenance Manual for specific fastening and latching

Sudden movement or accidental starting of the machine can cause

To prevent personal injury or death, perform the following:

Park the machine on a smooth level surface.

Lower the blade and or attachments to the ground.

Stop the engine and engage the parking brake.

Block the wheels and install the steering frame lock.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Remove the cooling system pressure cap slowly to relieve pressure.

QTY PART NUMBER NAME

1 506-0726 Hydraulic Oil Cooler Ar

QTY PART NUMBER NAME

3 9R-2613 Weld Boss

8. Locate clip (8) using the dimensions above.

Note: The ground boss (10) must be free of all paint.

8X-4711 Boss As (10) at (B) over, and (E) down to center.

Note: Do not remove tire.

Refer to Illustration 16 for torque tightening sequence:

a. Apply 100% torque to bolts numbered 1/5 and 2/6.

b. Apply 100% torque to bolts numbered 3 and 4.

c. Reapply 100% torque to bolts numbered 1/5 and 2/6.

a. Apply 80% of specified torque to bolts numbered 1/5 and 2/6.

b. Apply 80% of specified torque to bolts numbered 3/7 and 4/8.

c. Apply 100% of specified torque to bolts numbered 1/5 and 2/6.

d. Apply 100% of specified torque to bolts numbered 3/7 and 4/8.

19. Remove the following hardware from the handrail connector:

Two 8T-4244 Nuts (20)

Two 8T-4223 Hard Washers (21)

Two 5P-1076 Hard Washers (22)

Two 8T-4183 Bolts (23)

Two 6V-1874 Grommets (24)

Two 5P-7469 Clips (25)

One 115-3580 Plate (26)

Two 5P-7468 Clips (27)

21. Remove the 7I-5024 Handrail As (31).

22. Torque 5D-1026 Band Clamp to 7.5 ± 1 N·m (66.38062 ± 9 lb in).

Four 8T-4192 Bolts (33)

Four 5P-1076 Hard Washers (34)

Four 5C-7261 Nuts (35)

Four 8T-4224 Hard Washers (36)

Two 248-0102 U-Bolts (37)

25. Remove 8X-3178 Plate (39).

27. Remove the 272-1148 Grill As (44).

Low torque all bolts to 125 ± 20 N·m (90 ± 15 lb ft).

31. Position the 511-6656 Plate As (49) onto bumper surface.

33. Locate the previously installed blocks to the bumper.

34. Tack weld all blocks onto the bumper.

39. Assemble the following parts to the 511-6656 Plate As (49):

One 511-6669 Plate As (52)

One 511-6661 Plate As (53)

One 511-6664 Tube (54)

One 511-6660 Post As (55)