18/12/2019 Media Search - REHS8985 - 994K Wheel Loader Commissioning Procedure {0374, 1000, 7000, 7960, 7961}

18. Hold out the switch.

19. Turn the engine start switch to the START position.

20. Hold the switch in the START position for 10 seconds.

21. Repeat Step 17 and Step 19 three times.

22. Check all the fluid levels.

23. Maintain the fluids at the correct level.

24. Push the remote engine stop switch back to the RUN position.

25. Start the engine. Run the engine at low idle for 10 to 20 seconds.

Note: DO NOT operate the implement controls or the STIC.

26. Stop the engine and check all the fluid levels.

27. Maintain the fluids at the correct level.

28. Repeat Step 25 and Step 26 until the fluid levels do not change.

Break-In Procedure (Implement Cylinders)

Illustration 3 g06403243
(1) Lift cylinders
(2) Tilt cylinders

1. Check the hydraulic oil level.

2. Run the engine at low idle.

Note: Do not extend the tilt cylinders to full extension during the first two cycles. Do not extend the lift cylinders to
full extension during the first two cycles. Do not retract the tilt cylinders to full retraction during the first two cycles.
Do not retract the lift cylinders to full retraction during the first two cycles.

3. Place the lift cylinders in the assembled position.

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4. Extend the lift cylinders to 75 percent of the full stroke.

5. Retract the lift cylinder to 12.5 percent of the full stroke after four seconds of waiting.

6. Repeat Step 3 through Step 5 after four seconds of waiting.

7. Repeat Step 3 through Step 5 for five cycles. Allow the cylinders to extend and retract. Change directions after a
minimum of four seconds of waiting.

Note: Do not allow the relief valve to open.

8. Repeat Step 3 through 7 for the tilt cylinders.

9. Fully retract the lift cylinders.

10. Extend the tilt cylinders to 50 percent of the full stroke.

11. Make sure that the hydraulic oil level is below the full mark.

12. Install the cap for the implement hydraulic tank.

Operate the Automatic Lubrication System Manually

1. Calibrate both minimum and maximum fan speeds using Caterpillar ET.

Note: Autolube pump flow is tied to fan speed.

2. Operate the autolube system manually in order to lubricate the linkage pins.

3. Press the manual lubrication button.

4. Repeat Step 3 until grease is visible from the linkage pins.

Break-In Procedure (Pin)

Illustration 4 g06403264
Level position of the linkage pins
(1) Linkage pin
(2) Linkage pin

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1. Start with the loader bucket level on the ground.

2. Lubricate the new pin joints manually in order to force the grease between the pins and the seals.

3. Lubricate the new pin joints manually in order to force the grease from the relief fitting.

4. On machines that are equipped with an automatic lubrication system, the system can be activated manually in order
to grease the new pin joints.

5. On machines that are equipped with pins that are filled with oil, manual lubrication is not necessary.

6. Slowly raise the boom to the level position.

7. Check that pins (1) and (2) are at the same height.

8. Slowly move the loader bucket to the maximum RACK position of the tilt cylinder.

9. Check the maximum angle of the rack control position.

10. Slowly move the loader bucket to the maximum DUMP position of the tilt cylinder.

11. Move the loader bucket back to the horizontal position.

12. Lower the loader bucket to the ground.

13. Apply enough downward pressure in order to lift the front tires off the ground.

14. Release the downward pressure in order to lower the front tires to the ground.

15. Repeat Step 1 through Step 14 five more times.

16. Start with the loader bucket level on the ground.

17. Slowly raise the boom to maximum lift height.

18. Slowly move the loader bucket to the maximum RACK position of the tilt cylinder.

19. Slowly move the loader bucket to the maximum DUMP position of the dump stops.

20. Move the loader bucket back to the horizontal position.

21. Lower the loader bucket to the ground.

22. Apply enough downward pressure in order to lift the front tires off the ground.

23. Release the downward pressure in order to lower the front tires to the ground.

24. Refer to Step 2.

25. Repeat Step 16 through Step 24 five more times.

26. After the last lift and tilt cycle, lubricate ALL of the linkage pins.

27. Move the machine to a pile of loose material.

28. Load the loader bucket until the loader bucket is half full.

29. Raise the loader bucket to the level position.

30. Dump the loader bucket.

31. Lower the loader bucket to the ground.

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32. Apply enough downward pressure in order to lift the front tires off the ground.

33. Release the downward pressure in order to lower the front tires to the ground.

34. Refer to Step 2.

35. Repeat Step 27 through Step 34 five more times.

36. Use the same pile of loose material and load the loader bucket until the loader bucket is half full.

37. Raise the loader bucket to maximum lift height.

38. Dump the loader bucket.

39. Lower the loader bucket to the ground.

40. Apply enough downward pressure in order to lift the front tires off the ground.

41. Release the downward pressure in order to lower the front tires to the ground.

42. Refer to Step 2.

43. Repeat Step 36 through Step 42 five more times.

44. After the last lift and tilt cycle, lubricate ALL of the linkage pins.

45. Use the same pile of loose material and load the loader bucket with a normal heaped load.

46. Raise the loader bucket to maximum lift height.

47. Dump the loader bucket.

48. Lower the loader bucket to the ground.

49. Apply enough downward pressure in order to lift the front tires off the ground.

50. Release the downward pressure in order to lower the front tires to the ground.

51. Refer to Step 2.

52. Repeat Step 45 through Step 51 five more times.

53. After the last lift and tilt cycle, lubricate ALL of the linkage pins.

54. On machines that are equipped with an automatic lubrication system, refill the lubricant reservoir.

55. Stop the engine and check all the fluid levels.

56. Maintain the fluids at the correct level.

57. After all of the implements have been operated, purge all the air from the implement pilot system.

Precautions During Commissioning (Pin)

1. Inspect the machine to ensure that all the grease lines are in place and grease is visible around the joints.

2. Manually fire the injectors several times after the machine has started. testing should be stopped if any autolube
alarms are activated.

3. A lift arm power down against the ground is required every five lift and lower cycles. After the fifth cycle, level the
bucket and lower the linkage until the lift cylinders are fully closed. Hold for one second. If necessary, place blocks
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under the B pin end of the boom so that the front tire bulge is visibly reduced when the lift cylinders are fully
closed.

Operation after Break-In Procedure (Pin)

1. Check the new pin joint for noise or unusual motion for several shifts.

2. Check after the pin joint is replaced.

3. On machines that are equipped with an automatic lubrication system, make sure that the system is lubricating the pin
joints at the correct interval.

4. Check for fresh grease at the seals of the pin joint, if the machine is equipped with lip seals.

5. Check for fresh grease at the relief fitting, if the machine is equipped with face seals.

6. If the machine is equipped with an automatic lubrication system, reduce the lubrication interval after a pin joint is
replaced.

7. Lubricate the new pin joint at the middle and the end of each shift for several days after a pin joint is replaced.

Brakes - Purge

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, PERJ1017, "Dealer Service Tool Catalog"

for tools and supplies suitable to collect and contain fluids on Cat®
products.

Dispose of all fluids according to local regulations and mandates.

There must be no air in the hydraulic oil. Air in the system can prevent the complete application of the brakes.

Service Brakes

1. Move the machine to a hard, level surface that is dry and free of debris.

2. Install the steering frame lock.

3. Set the parking brake.

4. Check the oil level in the hydraulic tank for the steering system and for the braking system. Keep the hydraulic tank
full during the procedure.

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