994K Wheel Loader Commissioning Procedure {0374, 1000, 7000, 7960, 7961} Caterpillar

Wheel Loader

994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

Introduction

Table 1

Revision History
Revision	Summary of Changes
04	SMX prefix added to effectivity. Notice added for Tier 4 certified engine systems. Reference added for obtaining the most recent version of Cat ET. Graphics updated to include CEM and PETU serial plates. Added section "Mandatory Reporting for T4 Engines".

This Special Instruction contains the commissioning procedure that is required after the field assembly procedure of the 994K Wheel Loader is completed.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

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Personal injury or death can result from air in the oil for the brake hydraulic system. Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped. Air must not be in the oil for the brake hydraulic system to function properly.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

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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.

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NOTICE
This machine is equipped with a Tier 4 Certified Engine system that is configured to meet the emissions requirements mandated by the United States Environmental Protection Agency (EPA). Care must be taken to comply with all instructions within this document to ensure that the engine, as assembled (including the exhaust piping, DEF Fluid lines, and controls), performs as designed to meet and maintain Tier 4 emissions requirements. Also, to meet the EPA regulatory requirements related to recording the combination of engine and emissions components that will be placed into service with the machine. Return the required information to the address listed in the "Mandatory Reporting for Tier 4 Machines" Section.

Required Equipment for the Commissioning Procedure

The following items will be required when the machine is completed and prepared for the commissioning procedure.

• Special Publication, JEBD3003, "Caterpillar Electronic Technician Getting Started Guide"

• Special Publication, JERD2093, "Cat Common Services"

• Special Publication, JERD2124, "Electronic Technician Single Use Program License"

• Special Publication, JERD2129, "Electronic Technician Engine/Machine Subscription"

• Special Publication, JERD2137, "VIMS Dealer License - Dealers Only"

• Special Publication, JERD2138, "VIMS Annual Subscription - Dealer"

• 466-6258 Communication Adapter Group

• 127-9797 Cable Assembly (VIMSpc)

Note: With the release of Tier 4 Final engines, additional emissions control system components have been added to the engine to reduce the NOx output. The most recent version of Cat^® Electronic Technician (ET) must be used when connecting to the Electronic Control Modules. Refer to Special Instruction , REHS8170, "Comm Adapter 3 and Computer Settings for Tier 4 Final Engines" for instructions on properly setting up the computer and Comm3 adapter for use on Tier IV applications.

Procedure for Starting the Machine

Activate the Batteries

Table 2

Parts that are required in order to activate the batteries
Item	Qty	Part Number	Description
1	4	389-4802	Battery and Mounting Gp(1)

(1)	Each group contains two batteries.

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Illustration 1	g03582157
(1) Battery and mounting group

1. Open the battery compartment of the right side of the bumper platform. Locate the three battery groups (1), six batteries total, or the four battery groups (1), eight batteries total (If Equipped), that are in the battery compartment on the platform.

2. Make sure that battery lockout is engaged, or in the OFF position.
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   Illustration 2	g03582160
   Top view of battery (activation of battery)

3. Fill the batteries and charge the batteries. Refer to Special Instruction, REHS0458, "Activation of 101-4000 Batteries, 115-2421 Batteries, and 9X-9730 Batteries That Are Shipped Without".

Inspect the Machine Before Starting the Machine

1. Connect the steering frame lock link.

   Note: Refer to Operation and Maintenance Manual, SEBU9196, "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.

4. Maintain the engine oil at the correct level.

5. Fill cooling system.

6. Fill both hydraulic tanks with hydraulic fluid.

7. Fill the final drives and the differentials with oil.

8. Disconnect the case drain lines from four implement pumps.

9. Fill the case drain lines with oil.

10. Disconnect the case drain lines from two steering pumps.

11. Fill the case drain lines with oil.

12. Disconnect the case drain line from the brake actuation pump.

13. Fill the case drain line with oil.

14. Fill the transmission with oil.

15. The transmission oil level should be at the full mark on the sight glass.

16. Check on the machine and around the machine in order to verify that the machine is clear of personnel and clear of equipment.

17. Pull the remote engine stop switch.

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.

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)

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

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.

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 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

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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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   Illustration 5	g06402742
   Typical air purge screw for the service brakes (1) Air purge screw.

5. Connect a hose to air purge screw (1). Put the other end of the hose in a clear container.

6. Start the engine and run the engine at low idle.

7. Open air purge screw (1) so that oil can flow through the hose. Depress the brake pedal until the flow of oil from the hose is free of air bubbles.

8. Close the air purge screw. Repeat this procedure for each service brake, but purge only one service brake at a time.

9. Fill the hydraulic oil tank to the correct level.

10. If the service brakes seem spongy during operation, perform the procedure again.

Parking Brake

1. Place wood blocks in front of the tires and behind the tires.

2. Start the engine and allow the oil pressure to reach the cutout pressure. Stop the engine.
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   Illustration 6	g03857872
   Parking brake control switch

3. Lift tab and push the top of the parking brake control switch to activate the parking brake.
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   Illustration 7	g00110116
   Air purge screw for the parking brake (2) Air purge screw

4. Connect a hose to air purge screw (2) on the side of the parking brake housing. Put the other end of the hose in a clear container.

5. Slowly open air purge screw (2) so that oil can flow through the hose. Allow the oil to flow until there are no air bubbles in the oil. Close the air purge screw.

Break-In Procedure (Steering Cylinders)

1. Make sure that air is removed from the steering cylinders before pressurization of the system.

2. Check the hydraulic oil level.

3. Run the engine at low idle.

4. Turn the machine to the right and turn the machine to the left. Perform this action for three cycles. Change directions after a minimum of four seconds of waiting.

5. Run the engine at high idle. Repeat Step 4.

Steering Neutralizer Valve - Adjust

Note: The steering neutralizer valves prevent contact between the rear frame and the loader 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.
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   Illustration 8	g03582214
   Left side view of machine (upper pin of articulation joint) (1) Neutralizer plunger (2) Steering neutralizer valve

2. Adjust neutralizer plunger (1) the entire way in ( thus allowing the machine the ability for frames to contact each other during steering). Warning: Take care not to allow the frames to contact each other with any speed or force, permanent damage can occur.

3. At low idle engine speed, slowly articulate the machine to the left. Utilize a spotter to identify when the frames are about to touch. Continue to articulate as slow as possible until the frames touch. Drive machine in a complete circle to remove the tire wrap. Ground the bucket immediately to prevent steering from drifting to the right. Shut machine off and engage the parking brake.

4. Adjust plunger out until it just touches the tip of neutralizer valve (2). It can be hard to see, so use a thin metal ruler to feel when the plunger first contacts the tip of the neutralizer valve.

5. Repeat Steps 2 through 4 in the other direction.

6. Articulate machine back straight and shut down the engine.

7. Using a small ruler as a guide, adjust each plunger out 20 mm (0.8 inch).

Fine-Tune the Steering Neutralizer Valve

Illustration 9	g06403452
View of left turn frame stop (3) Steering stop on loader frame (4) Steering stop on rear frame

1. On level ground, run the engine at low idle, fully rack the empty bucket and raise it off the ground.

2. Start the machine fully articulated to the right, apply a full steering left command, turn the machine all the way to the left until end of travel, then apply a full steering right command, turn the machine all the way to the right until end of travel.

3. Repeat Step 2 in 200 RPM increments until, Just BEFORE the frames would contact or high idle is achieved.

4. Measure and record the distance between frame stops (3) and (4) in each direction, during the last high idle test. Distance between frame stops should be between 50 mm (2 inch) and 80 mm (3.15 inch).

5. If space is larger than 80 mm (3.15 inch) in either direction, adjust the neutralizer plunger ( on corresponding side) IN 2 mm (0.1 inch). If space between frames is smaller than 50 mm (2 inch), adjust the neutralizer plunger ( on corresponding side) OUT 2 mm (0.1 inch). Repeat Steps 2 through 4 until frame spacing is within 50 mm (2 inch) and 80 mm (3.15 inch).

Fast Fill Automatic Lubrication Service

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Illustration 10	g03838425
Service center (1) Fast fill service panel (2) Access cover

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Illustration 11	g03838435
Fast fill service panel (3) Transmission oil fast fill port (4) Engine oil fast fill port (5) Cooling system coolant fast fill port (6) Oil renewal system fast fill port (7) Automatic lubrication system fast fill port (8) Hydraulic system oil (implement, hydraulic fan) fast fill port (9) Hydraulic system oil (implement, hydraulic fan) ecology drain (10) Hydraulic system oil (steering, brake) ecology drain (11) Hydraulic system oil (steering, brake) fast fill port

1. Open access cover (2) for the fast fill automatic lubrication service on the left-hand side of the rear frame.

   Note: The fast fill automatic lubrication service will be located to the rear of the machine.

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 65 ± 15 mm (2.6 ± 0.6 inch) gap.

Reference: Refer to Service Manual, UENR3333, "994K Wheel Loader Field Assembly", "Check the Adjustment of the Steering Neutralizer Valve" for additional information.

Articulate the machine. Grease 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 994K Wheel Loaders.

Update Product Link Elite Configuration of the Machine

An update of the Product Link Elite configuration is necessary when the machine is first delivered. After the machine is assembled, connect a computer to the service port and run Cat ET.

1. Select the "Product Link Elite" ECM when prompted.

2. Go to the "Service" menu and select "ECM Date/Time".

3. Follow the instructions that are shown in Cat ET to update the time zone on the Product Link Elite ECM.

4. Go to the "Service" menu and select "Configuration".

5. Under the list of configurations for the "Product Link Elite", select "General Information".

6. Under the list of parameters for "General Information", select "Equipment ID" and click the "Change" button.

7. Follow the instructions that are shown in Cat ET to assign the equipment number for the machine.

8. Close Cat ET and disconnect the computer from the machine.

Power Train

Engine

1. Run the engine at normal operating temperature and place the transmission in NEUTRAL.

2. Engine speed at high idle should be 1700 ± 10 rpm.

3. Engine speed at low idle should be 750 ± 10 rpm.

4. Verify the idle speeds according to the values on the engine performance specification.

5. See the engine information plate for the values.

6. Fully press the right service brake and release the parking brake.

7. Shift into second speed forward to stall the torque converter,

8. Slowly push the throttle pedal to full extension to reach an engine full load condition. CAUTION: do not stall the converter at full throttle for more than 10 seconds as the converter can overheat.

9. Boost pressure is specified as 155 kPa (22.5 psi) ( 130 to 180 kPa (19 to 26 psi)).

10. The boost pressure can also be specified by 1162 mm (46 inch) of HG ( 975 to 1350 mm (38 to 53 inch)).

11. Oil pressure should be 159 to 600 kPa (23 to 87 psi) at low idle speed.

12. Oil pressure should be 400 to 650 kPa (58 to 94 psi) at full load.

13. Operate the machine at the full load rpm of 1588 ± 50 rpm.

14. Fuel pressure should be 415 to 450 kPa (60 to 65 psi).

For machines with serial number prefix SMX, proceed to the

Perform the Aftertreatment Functional Test S/N:SMX1-UP

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NOTICE
Confirm that the latest software vintage is flashed to the engine and aftertreatment prior to performing functional testing.

1. Use a laptop computer to open Cat Electronic Technician (ET).
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   Illustration 12	g03825128

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   Illustration 13	g06411562
   Clean Emissions Module (CEM) serial plate location

   Note: The serial number plate for the Clean Emissions Module (CEM) is on the mounting structure (cradle) of the CEM.

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   Illustration 14	g06414824
   Pump Electronic Tank Unit (PETU) serial plate location

2. Confirm correct serial numbers for the Clean Emissions Module (CEM) and Pump Electronic Tank Unit (PETU).

   1. Check the value of the "Factory Installed Aftertreatment #1 Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.

   2. Check the value of the "Aftertreatment DEF Pump Electronics Tank Unit Identification Number" and ensure that the serial number is correct. If incorrect, enter the correct number.
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   Illustration 15	g03825970

3. From the toolbar, select "Diagnostics" then "Diagnostic Tests".
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   Illustration 16	g03825987

4. Select "Aftertreatment Functional Test" and click "Start".
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   Illustration 17	g03825152

5. Read and understand the warning. Click "OK" to proceed to the test.
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   Illustration 18	g03825157

6. Click "Next" to proceed to the test.

Torque Converter

Note: Perform torque converter pedal sensor and impeller clutch solenoid calibration if there is an "Active Calibration Required" (FMI 13) fault active for those components.

1. Press the "HOME" button on the information display module in order to bring up the "HOME" menu. Select "Service". Press the "OK" button.

2. Select "Calibrations" from the "Service" menu. Press the "OK" button.

3. Select "Transmission" from the "Calibrations" menu. Press the "OK" button.

4. The information display module may ask for a password. Enter the password. Press the "OK" button in order to continue. Note: The default password is "0".

5. Select "IC Solenoid Cal" from the "Transmission" menu. Press the "OK" button in order to begin the calibration of the impeller clutch solenoid.

6. Follow the instructions that are shown on the information display in order to perform the calibration.

7. For additional information, refer to Testing and Adjusting, UENR4904, "994K Wheel Loader Power Train".

Torque Converter Stall

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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.

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Illustration 19	g03582240
Pressure tap location (8) Test port - "LUBE" (9) Test port - "TC-IN" (10) Test port - "TC-OUT" (11) Test port - "LU-C" (12) Test port - "IMP-C" (13) Test port - "STR-PILOT" (14) Test port - "SPEED" (15) Test port - "DIR-C"

1. Install a hose and a 1400 kPa (200 psi) pressure gauge on pressure tap (10) "TC-OUT". Refer to Illustration 20.

2. Engage the parking brake, and place the transmission in NEUTRAL.

3. Start the engine.

4. Display the engine rpm on the information display window.

5. Be sure that the high idle rpm for the engine is correct at 1700 ± 10 rpm.

6. Be sure that the power train oil is at normal operating temperature.

7. Apply the service brakes with the service brake pedal.

8. Release the parking brake.

9. Shift the transmission into SECOND SPEED FORWARD.

10. 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.

11. The engine rpm should be 1588 ± 50 rpm with the torque converter in the stall condition.

12. The pressure on the gauge should be 470 ± 138 kPa (68 ± 20 psi).

13. Shift the transmission to NEUTRAL and bring the power train oil temperature back to the normal operating temperature.

14. Stop the engine and remove the test equipment.

Torque Converter Lockup Clutch "LU-C"

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Illustration 20	g03582240
Pressure tap location (8) Test port - "LUBE" (9) Test port - "TC-IN" (10) Test port - "TC-OUT" (11) Test port - "LU-C" (12) Test port - "IMP-C" (13) Test port - "STR-PILOT" (14) Test port - "SPEED" (15) Test port - "DIR-C"

1. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap (11) "LU-C". Refer to Illustration 20.

2. Move the lockup clutch switch to the ENABLE position.

3. Engage the parking brake, and place the transmission in NEUTRAL.

4. Start the engine.

5. Apply the service brakes and release the parking brake.

6. Place the machine in SECOND SPEED FORWARD.

7. Operate the machine at maximum speed, and observe the pressure reading on the gauge.

8. Make sure that the left service brake pedal or the right service brake pedal are not depressed.

9. If the left service brake pedal or the right service brake pedal is depressed, the lockup clutch will not engage.

10. The maximum stabilized pressure should be 2413 ± 70 kPa (350 ± 10 psi).

Torque Converter Impeller Clutch Pressure "IMP-C"

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Illustration 21	g03582240
Pressure tap location (8) Test port - "LUBE" (9) Test port - "TC-IN" (10) Test port - "TC-OUT" (11) Test port - "LU-C" (12) Test port - "IMP-C" (13) Test port - "STR-PILOT" (14) Test port - "SPEED" (15) Test port - "DIR-C"

1. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap (12) "IMP-C". Refer to Illustration 20.

   Note: Impeller clutch pressure can also be observed through the information display.

2. Engage the parking brake, and place the transmission in NEUTRAL. Start the engine.

3. Move the reduced or maximum rimpull switch to the MAXIMUM position.

4. Operate the engine at high idle speed and observe the pressure reading on the gauge.

5. The maximum pressure should be no lower than 1900 kPa (275 psi) with left pedal not depressed.

6. Operate the engine at high idle speed and completely depress the left pedal.

7. Observe the pressure reading on the gauge.

8. The default setting is 150 to 600 kPa (22 to 87 psi).

9. Release the left pedal.

10. Move the machine to a pile and stall the torque converter by pushing the bucket into the pile while in the first speed forward gear; do not use any implements. CAUTION: do not stall the converter for too long as that will cause an overheat warning.

11. Press the reduced rimpull button on the keypad.

12. Observe the pressure reading on the gauge. The pressure should decrease and be lower than the reading at the maximum position.

13. Repeat Steps 11 and 12 for the other reduced rimpull settings.

Transmission

1. Bring the engine and the transmission to normal operating temperatures, and put the transmission in NEUTRAL.

2. Operate the engine at high idle speed.

3. The speed clutch pressure tap (14) "SPEED-C" should be 2760 ± 140 kPa (400 ± 20 psi).

4. The direction clutch pressure tap (15) "DIR-C" should be 2170 ± 140 kPa (315 ± 20 psi).

5. The transmission lubrication pressure tap (8) "LUBE" should be no less than 110 kPa (16 psi).

6. Operate the engine at low idle speed.

7. The transmission lubrication pressure tap (8) "LUBE" should be no less than 7 kPa (1 psi).

8. The differential pressure is the difference between pressure tap (14) "SPEED-C" and pressure tap (15) "DIR-C" values.

9. The differential pressure should be 590 ± 35 kPa (86 ± 5 psi).

10. Partially depress the left pedal.

11. The impeller clutch must slip in all gears.

12. The transmission control switch must operate correctly in each gear.

13. The backup alarms must activate immediately when the transmission control lever is shifted into reverse.

14. The alarms must be clearly audible and the alarms must function until the transmission is returned to NEUTRAL.

Torque Converter Inlet Pressure "TC-IN"

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Illustration 22	g03582240
Pressure tap location (8) Test port - "LUBE" (9) Test port - "TC-IN" (10) Test port - "TC-OUT" (11) Test port - "LU-C" (12) Test port - "IMP-C" (13) Test port - "STR-PILOT" (14) Test port - "SPEED" (15) Test port - "DIR-C"

1. Connect a hose to pressure tap (9) "TC-IN". Connect a 1400 kPa (200 psi) pressure gauge to the opposite end of the hose. Refer to Illustration 20.

2. Start the engine and run the engine at high idle.

3. The pressure on the gauge must not exceed 900 kPa (130 psi) with cold oil.

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 90 seconds. 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 parking brake indicator will be red when the brake system pressure is below 6900 kPa (1000 psi).

2. Engage the parking brake.

3. Move the transmission from the NEUTRAL position and select any gear.

4. The action lamp will be blinking red.

   Note: If the machine is moving faster than 1 kph (0.6 mph) with the parking break engaged, the action alarm will sound.

5. Move the transmission to the NEUTRAL position. Engage the parking brake.

6. The parking brake indicator on the dash will be lit.

Brake Accumulator Charging Valve

1. Operate the engine at low idle speed. The accumulator pressure must increase to 14313 to 15692 kPa (2076 ± 2276 psi).

2. Pump brake pedal repeatedly and check that the accumulator pressure returns to 14313 to 15692 kPa (2076 ± 2276 psi)

3. Check the actuation pressure for the brakes at the brake control group.

4. The actuation pressure should be 5494 ± 250 kPa (797 ± 36 psi) while the right brake pedal or the left brake pedal is depressed.

5. The residual pressure in both cases should be a maximum of 140 kPa (20 psi).

6. Purge the brakes at each wheel.

Tires

1. Inflate the front tires to a working pressure of 700 kPa (100 psi).

2. Inflate the rear tires to a working pressure of 585 kPa (85 psi).

   Note: Consult with the representative from the tire manufacturer for recommended tire pressures for your working conditions.

Hydraulics

Steering Check

Show/hide table

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.

Illustration 23	g03582240
Pressure tap location (8) Test port - "LUBE" (9) Test port - "TC-IN" (10) Test port - "TC-OUT" (11) Test port - "LU-C" (12) Test port - "IMP-C" (13) Test port - "STR-PILOT" (14) Test port - "SPEED" (15) Test port - "DIR-C"

1. Operate the engine at high idle speed.

2. The pilot pressure at test port (13) "STR-PILOT" should be 3900 ± 400 kPa (566 ± 58 psi) when the STIC is not active.

3. Place the machine on a dry level concrete surface.

4. Release the brakes, and run the engine at high idle speed.

5. Install the steering lock.

6. Stall the steering against the steering lock. Steering pressure should be 31000 ± 750 kPa (4496 ± 109 psi).

7. Remove the steering lock.

8. The turning time between the right turn stop and the left turn stop should be 3.7 to 4.6 seconds.

9. The difference between steering left and steering right should be no more than 0.3 seconds.

10. Apply the service brakes and measure the turning time between the right turn stop and the left turn stop.

11. The time must not vary more than 0.3 seconds from the time in Step 8.

12. Place the machine on a dry level concrete surface, and release the brakes.

13. Place the machine in the straight ahead position with the loader bucket slightly off the ground.

14. 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.

Electro-hydraulic

Note: Information display can be used in order to monitor implement pilot pressure, left main valve pressure, and right main valve pressure.

1. Operate the engine at low idle speed. The pilot pressure should be 3450 ± 350 kPa (500 ± 50 psi).

2. Connect a computer to the service port and run Cat ET. Follow Cat ET implement calibration procedure.

   • Connect to "Implement ECM"

   • Go to "Service Menu"

   • Select "Calibrations"

   • Complete "Lever Sensors", "Linkage Sensors", "Pumps"and "Valves" calibrations.

3. Operate the engine at high idle speed and place the transmission in NEUTRAL position. The left and right main implement valve pressure should be 2500 ± 100 kPa (360 ± 15 psi).

4. The loader bucket must be empty.

5. Move the lift control lever and tilt control lever in all possible operating positions.

6. The lift and tilt function should operate properly.

7. Operate the engine at high idle speed.

8. The control levers must remain in the NEUTRAL position.

9. The lift and tilt cylinders must not move.

10. Operate the engine at low idle speed. The left and right main implement valve pressure should be 2500 ± 100 kPa (360 ± 15 psi).

11. Fully lower the bucket to the ground. Move the lift control lever post the lower detent position and return the lift control lever to neutral. The float indicator on the dash should be lit and the bucket should be floating on the ground. Fully raise the bucket to max lift height. Turn off the engine. Move the lift control lever to the lower position and hold until the bucket is fully lowered. The bucket should lower slowly to the ground.

Implement

1. Start the engine.

   Note: The oil temperature should be 50 to 80° C (122 to 190° F) at high idle speed

2. Connect a communications adaptor to the machine service port in the cab. Start Cat ET on the computer.

3. Select the "Implement 994K" ECM when prompted by Cat ET.

4. Go to the "Diagnostics" menu and select "Diagnostic Tests".

5. Select "Implement Main Relief Pressure Test" in the window and press the "Start" button.

6. Follow the Cat ET procedures. Ensure that all two main relief tests are selected when prompted.

7. Each main relief pressure should read 31626 ± 700 kPa (4587 ± 102 psi).

8. Select "Service Modes" from the "Service" menu. Press the "OK" button.

9. Select "Lift Time Check" from the "Service Modes" menu. Press the "OK" button.

10. Select "All Pumps" from the "Lift Time Check" menu and press the "OK" button in order to begin the lift time check with all pumps.

11. Follow the instructions that are shown on the Cat ET display. The lift times should be 12 to 13 seconds (SL or HL).

12. Select "Service Modes" from the "Service" menu. Press the "OK" button.

13. Select "Drift Checks" from the "Service Modes" menu. Press the "OK" button.

14. Select "Lift Cylinder" from the "Drift Checks" menu and press the "OK" button in order to begin the lift cylinder drift check.

15. Follow the instructions that are shown on the Cat ET display.

16. Repeat Steps 13 through 15 in order to run the tilt cylinder drift check. Select "Tilt Cylinder" in Step 14 in order to run this test.
    Show/hide table

    Table 3

    Hydraulic Oil Temp	Lift Drift	Tilt Drift
    40° - 49°C (104° - 120°F)	5 mm (0.2 inch)	2 mm (0.07 inch)
    50° - 59°C (122° - 138°F)	7 mm (0.3 inch)	3 mm (0.12 inch)
    60° - 69°C (140° - 156°F)	10 mm (0.4 inch)	4 mm (0.16 inch)

17. The allowable drift rates are dependent on oil temperature and run over a one minute period. Refer to Table 3 for additional information.

Leakage

1. Clean all oil from the connections and the fittings.

2. Move all cylinders through the full range of motion.

3. Hold the control levers at full displacement at the end of cylinder stroke in order to obtain relief valve pressure.

4. 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 60 seconds.

Operator 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.
   Show/hide table

   Illustration 24	g03839157
   View of right side console (1) Reduced rimpull button

2. Ensure that the proper gear is shown in the dash gauge cluster. The backup alarm should sound when in a reverse gear.

3. Depress the reduced rimpull button (1) on the keypad. Each depress of the button will turn off an LED above the button. Continue to depress the button until all LEDs above the button are lit.

Parking Brake Control

1. Lift the interlock tab and press the top of the parking brake switch in order to activate the parking brake.

   Note: The interlock tab is red and the switch is located below the dash.

2. Select first gear and engage the transmission in either direction. The transmission should not engage and a "Transmission Neutralized" message should appear on the information display.

3. Return the transmission to NEUTRAL.

4. Select SECOND or THIRD gear and engage the transmission in either direction. The transmission should engage and the alert indicators will be blinking red and an audible alarm will sound. A "Parking Brake On" message should appear on the information display.

5. Ensure that the proper indicator lamp comes on for the gear that is selected.

6. Return the transmission to NEUTRAL.

7. Lift the interlock tab and press the bottom of the parking brake switch in order to release the parking brake.

Throttle Control

1. Depress the accelerator pedal for 33 degrees when the engine is running.

2. The pedal should be at the mechanical stop at the bottom side of the pedal.

3. The engine must be running at high idle speed.

4. Release the pedal.

5. The pedal must automatically return to the low idle position.

6. Depress the throttle lock enable keypad button. A light above the button and the throttle lock enable indicator in dash gauge cluster should be lit.

7. Depress the throttle control in order to achieve the desired engine rpm.

8. Depress the "Set/Decel" button to set the throttle.

9. Press the right brake pedal in order to disengage the throttle lock.

10. Depress the "Resume/Accel" button in order to resume the throttle setting.

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.

2. Depressing the pedal will reduce the output torque of the torque converter.

3. The torque should be 25 percent of the output torque when the impeller clutch is enabled.

4. Depress the left pedal further.

5. The machine will respond according to the next steps.

6. Apply the brakes at all four wheels.

7. The brake lights at the rear of the machine will illuminate.

Seat Controls

Check the following adjustments:

• Seat travel: 150 mm (5.9 inch) total

• Seat height: 75 mm (3 inch) total

• Seat suspension: adjustable

• The seat cushion is adjustable: two positions

• 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 lap of the operator. 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.

Electro-hydraulic Controls for Loader Bucket

1. Control the bucket to the desired start of loading position. The bottom of the bucket should be level with the ground and be above a foot off the ground.

2. Press and hold the rack kickout set button on the keypad until a beep is heard. The rack kickout position is now set.

3. Press and hold the lower kickout set button on the keypad until a beep is heard. The lower kickout position is now set.

4. Raise the bucket to the desired position for the raise kickout. Press and hold the raise kickout set button on the keypad until a beep is heard. The raise kickout position is now set.

5. Push the tilt lever forward until the bucket is in the fully dumped position.

6. Pull the tilt lever rearward past the soft detent and release the tilt lever. The tilt lever should return to the neutral position and the loader bucket should smoothly stop at the rack kickout position.

7. Push the lift lever forward past the soft detent and release the lift lever. The lift lever should return to the neutral position and the loader bucket should smoothly stop at the lower kickout position.

8. Pull the lift lever rearward past the soft detent and release the lift lever. The lift lever should return to the neutral position and the loader bucket should smoothly stop at the raise kickout position.

9. Disable the electrohydraulic controls by pressing the implement lockout switch to the active position.

10. Move the lift or tilt levers in any direction. The loader bucket should not move.

11. Enable the electrohydraulic controls by pressing the implement lockout switch to the disable position.

12. Control the bucket down to the lower position.

Instrument Panel

1. Turn the engine start switch key to the ON position. Power is now supplied 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 window wiper blades.

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. 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

   1. With the engine stopped, turn the start dial key to the ON position.

   2. Turn the blower fan dial to the LOW position. Then, turn the blower fan dial to the HIGH position. A normal sound must be heard at both fan speeds.

2. Heating

   1. Press the A/C control switch to "Heat" position.

   2. Turn the temperature dial toward the "Hot" region.

      Note: The engine must be running at normal operating temperature and the valves for the heater lines must be open.

3. Air flow

   1. Turn the blower fan dial to the LOW position or the HIGH position.

   2. Check for air flow. There must be air flow at the dash assembly under the front window wiper blades. There must be air flow on both sides of the seat support.

Heated Mirrors (If Equipped)

1. Depress the heated mirrors button on the keypad. Confirm that the mirrors are heated in five minutes.

Backlight Dimmer

1. Depress the backlight dimmer button on the keypad. Confirm that the LEDs, keypad buttons, advisor module, and gauge cluster are dimmer then before.

2. Continue to depress the backlight dimmer on the keypad until the LEDs, keypad buttons, advisor module, and gauge cluster are at fully lit.

Manual Autolube

1. Depress the manual lube button on the keypad. Confirm that the autolube system is running and completes a cycle without an autolube event being issued in Cat ET or in the advisor module.

Window Wiper Blades

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

Note: Operate the machine for 10 hours in FIRST gear or SECOND gear. DO NOT operate the machine in THIRD gear during the break-in period.

Note: Traveling at high speed should be avoided until the machine has reached at least 10 hours of normal low speed operation. The machine should be stopped at every half mile for 30 minutes. The speed of the machine should be varied if the machine must be moved from the assembly position to the work area. This precaution should be emphasized to the customer before the delivery of the machine. Failure to follow this precaution could result in early overheating of the drive line components.

1. Operate the machine for a minimum of 15 minutes. The operation must also include simultaneous operation of the implement system, the steering system, and the braking system.

Any indication of improper operation must be corrected. Improper operation can include the following:

• Harsh braking

• Improper linkage movements

• Jerky steering

• Unusual noises

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

1. Connect a computer to the service port and run Cat ET. Follow Cat ET payload calibration procedure.

   1. Connect to "Implement ECM"

   2. Go to "Service Menu"

   3. Select "Calibrations"

2. Select "Payload System Calibration" under Implement ECM. Press the "Start" button.

3. Check "Empty Bucket Weight Calibration" and "Full Bucket Weight Calibration", then click "Begin".

4. Follow the instructions that are shown on the Cat ET screen in order to run the calibration.

5. It is recommended to load the bucket with material about 110-115 percent of the rated payload to run the "Full Bucket Weight Calibration".

6. Go to "Service", select "Configuration". Go to "Production Measurement Settings" under Implement ECM. If the calibration payload can be measured by truck scale, enter the measured bucket payload to "Payload Control System Calibration Weight".

Target Weight for the Loader Bucket

Note: Refer to System Operations, UENR6738, "Payload Control System" for more information.

The target weight setting of the loader bucket refers to the target payload weight of the material that is lifted by the machine. The target weight setting can be adjusted for the changes in the loader bucket that is attached to the machine.

If a lighter loader bucket is attached to the machine, the target weight setting can be increased accordingly. If a heavier loader bucket is attached to the machine, the target weight setting can be decreased accordingly.

Note: An overload warning will be triggered when the bucket weight, measured by the loader payload system, exceeds 116.5 percent of the target weight setting.

Note: The loader payload system must be recalibrated when a different loader bucket is installed on the machine.

1. In Cat ET, go to "Service" menu, select "Configuration".

2. Select "Production Measurement Settings" under "Implement ECM".

3. Enter the target bucket payload under "Loader Bucket Payload Target Weight".

Configure Payload Control System

Note: The customer should complete the "Customer Defined Payload Control System Information" form prior to the commissioning procedure and payload calibration. The machine configuration should be customized to the customers specifications.

1. In Cat ET, go to "Service" menu, select "Configuration".

2. Select "Production Measurement Settings" under "Implement ECM".

3. Refer to "AUTO TRUCK ID ENABLE" and "AUTO MATERIAL ID ENABLE" from the information form to select the desired configuration.

4. Set the weigh activation and range parameters under "Production Measurement Advanced Setting". Refer to "PAYLOAD WEIGH ACTIVATION LIFT POSITION" and "PAYLOAD WEIGH RANGE CONFIGURATION" from the information form to configure the weigh activation height and range parameters.

5. Set the configuration for the payload horn feature under "Production Measurement Advanced Setting". Refer to "STORE PAYLOAD DATA HORN CONFIGURATION" from the information form.

6. Set the configuration for the payload overload warning feature under "Production Measurement Advanced Setting". Refer to "PAYLOAD OVERLOAD WARNING ENABLE" from the information form.

7. Connect a computer to the VIMS data port inside the operator cab and start VIMSpc.

8. Click the "Connect" button to establish communication with the Product Link Elite ECM.

9. Once a connection has been established, click the "Real Time" button and a webpage will open inside the VIMSpc window.

10. Click on "LISTS" at the top of the webpage.

11. Click on "MaterialID" on the left side of the webpage. Enter the data from the information form to the webpage.

12. Repeat Step 11 and select "LoadsiteID".

13. Repeat Step 11 and select "DelayCodes".

14. Repeat Step 11 and select "TruckID".

Customer Defined Payload Control System Information

Table 4

Loader Payload Basic Setup(1)
Menu Selection	Parameter	Description
Auto Truck ID Enable	Enabled	Truck ID selection screen will be shown when payload data is stored.
	Disabled	Truck ID selection will not be prompted when payload data is stored.
Auto Material ID Enable	Enabled	Material ID selection screen when payload data is stored.
	Disabled	Material ID selection will not be required when payload data is stored.

(1)	Basic payload settings that can be configured by the user.

Table 5

Loader Payload Advanced Setup(1)
Menu Selection	Parameter	Description
Payload Overload Warning Enable	Enabled	When the loader bucket payload target weight is exceeded, a "Level 2" event will be triggered.
	Disabled	No events will be triggered when the loader bucket payload target weight is exceeded.
Store Payload Data Horn Configuration	Sound Horn	The machine horn will sound for 400ms when payload data is stored.
	Do Not Sound Horn	The machine horn will not sound when payload data is stored.
Payload Weigh Activation Lift Position	Default is "50%"	This parameter is the same as the bottom of the weigh range, the position in percent of the calibrated lift linkage range where data capture for calculating a payload weight starts. The minimum value is 20% and maximum is 75%. This value should be high enough that the weigh is triggered after digging is complete.	Trigger payload weigh at:
			%
Payload Weight Range Configuration	Default is "15%"	This parameter is the amount of lift linkage travel, starting at the weigh activation point, over which data is captured to calculate a weight from. Adding this value to the weigh activation position will give you the top of the weigh range. The minimum value is 15% and the maximum value is 70%. Caterpillar recommends that this value is kept as small as possible.	Calculate payload across the lift:
			%

(1)	Advanced payload settings that can be configured by the user.

Site material naming preferences can be specified. The CPM material ID page in VIMSpc is used to edit, add to, rearrange, and delete material in the list. The following table for the material IDs.

Table 6

Number	Default Description	Custom Description
1	Material 1
2	Material 2
3	Material 3
4	Material 4
5	Material 5
6	Material 6
7	Material 7
8	Material 8
9	Material 9
10	Material 10

The PCS loadsite ID page in VIMSpc is used to edit, add to, rearrange, and delete loadsites in the list. Use the following table for the loadsite IDs.

Table 7

Number	Default Description	Custom Description
1	Unknown
2	Loadsite 1
3	Loadsite 2
4	Loadsite 3
5	Loadsite 4
6	Loadsite 5
7	Loadsite 6
8	Loadsite 7
9	Loadsite 8
10	Loadsite 9

Note: Refer to System Operations, UENR6738, "Payload Control System" for more information about the configuration parameters.

Activate Product Link

Refer to Systems Operation, RENR7911, "Product Link 121S/300" for information on how to activate and configure product link.

Mandatory Reporting for Tier 4 Machines

In the cases where the aftertreatment (CEM and PETU) is not applied to the engine in the engine manufacturing assembly facility, the dealer/distributor who completes the assembly must meet the respective regulatory requirements (EPA- 40 C.F.R. § 1068.260) which are also included in the AFTERTREATMENT ASSEMBLY AGREEMENT established between the dealer/distributor and Caterpillar. The dealer/distributor obligations include adherence to the provided assembly and testing instructions, and the return (to Caterpillar) of the part and serial number relationship of the engine and applied aftertreatment (both CEM and PETU and SOFTWARE).

Completion of the activities outlined below, satisfies compliance with the required dealer/distributor obligations

1. Ensure adherence to the provided assembly and testing instructions for the engine and aftertreatment system.

2. Verify the aftertreatment system is functioning properly by completing the aftertreatment system functional test.

3. Confirm the system has no active faults.

4. Generate a product status report. Ensure all available ECMs are included.

5. Send a copy of the product status report to the following email address:

   Emissions_Compliance@cat.com

Checks Before Delivery of 994K 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. Do all the checks and verify that all the systems function properly.

Refer to Service Manual, UENR4904 and Operation and Maintenance Manual, SEBU9196 in order to correct any system malfunction. Any system malfunction must be corrected before the machine is delivered.

After the checklist is complete, sign your name and the name of the dealer.

Make copies, and mail to the address provided.

Caterpillar, Inc.
Attention: LWL Product Support
994K Wheel Loader
P.O. Box #348
Aurora, IL 60507

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 machines 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 seat. YES_____ NO_____

   • Does the horn function correctly? YES_____ NO_____

   • Does the window 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_____

   • Does the dead engine lower function correctly? YES_____ NO_____

   • Check the implement functions. Lift - Raise/Lower YES_____ NO_____ Tilt - Raise/Lower YES_____ NO_____

   • Do the throttle controls function correctly? 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, SEBU9196, "994K Wheel Loader" for the correct procedure. YES_____ NO_____

6. Does the prelube motor turn off before the engine starts? YES_____ NO_____

7. Were all the fluid levels rechecked? YES_____ NO_____

8. Were any unusual noises or leaks corrected? YES_____ NO_____

9. Were all the lubrication hose assemblies filled with grease before installation? YES_____ NO_____

10. Is the auto lube system functioning correctly? YES_____ NO_____

11. Were all of the quality requirements fulfilled? Were all variances corrected prior to releasing the machine to the customer? YES_____ NO_____

12. Was the backup alarm function checked? YES_____ NO_____

13. Is the machine repainted to factory satisfaction? YES_____ NO_____

14. Was there any damage during shipment? YES_____ NO_____

15. Were there any parts short from the factory? YES_____ NO_____

16. Name of the person making the checks:

    • Hydraulic____________________

    • Electrical____________________

    • Structural____________________

    • Other____________________

17. Comments:

    a.____________________

    b.____________________

    c.____________________

    d.____________________

    e.____________________

    f.____________________

    g.____________________

    h.____________________

    i.____________________

    j.____________________

    k.____________________

    l.____________________

    m.____________________

    n.____________________

    o.____________________

    p.____________________

    q.____________________

    r.____________________

    s.____________________

    t.____________________

Table 8

Specifications
Description	Condition	Specification	Actual	Comment
Power Train
Engine RPM	High Idle	1700 ± 10 rpm
Engine RPM	Low Idle	750 ± 10 rpm
Boost Pressure	Torque Converter Stall	minimum of 130 kPa (19 psi) maximum of 180 kPa (26 psi)
Oil Pressure	Low Idle	minimum of 159 kPa (23 psi)
Oil pressure	Full Load	minimum of 400 kPa (58 psi)
Fuel Pressure	1000 rpm and Full Load	415 kPa (60 psi) to 450 kPa (65 psi)
Torque Converter
Engine Rpm	Torque Converter Stall	minimum of 1588 ± 50 rpm
Torque Converter Outlet	-	470 ± 138 kPa (68 ± 20 psi)
Torque Converter Lockup Clutch	-	2413 ± 70 kPa (350 ± 10 psi)
Torque Converter Impeller Clutch	High Idle, Pedal Released	Minimum of 1900 kPa (275 psi)
Torque Converter Inlet Pressure	High Idle	Maximum of 900 kPa (130 psi)
Transmission
P1 Speed Clutch Pressure	High Idle	2760 ± 140 kPa (400 ± 20 psi)
P2 Direction Clutch Pressure	High Idle	2170 ± 140 kPa (315 ± 20 psi)
Transmission Lubrication Pressure	High Idle	Minimum of 110 kPa (16 psi)
Transmission Lubrication Pressure	Low Idle	Minimum of 7 kPa (1 psi)
P1-P2 Differential Pressure	High Idle	590 ± 35 kPa (85 ± 5 psi)
	Partially depress the left pedal.	Torque converter output should be 25% of the torque at the lockup clutch.
	Shift the transmission.	The transmission shifts smoothly in all gears.
Parking and Service Brakes
Brake System Pressure	The pressure is below 6900 kPa (1000 psi).	The alert indicator for the parking brake must be red.
	With the parking brake engaged, shift the transmission to any gear except neutral.	The alarm on the instrument panel must sound intermittently and the respective gear indicator must turn on.
Brake System Pressure in the normal range	Engage the parking brake.	The alert indicator for the parking brake must be red.
Brake System Pressure at maximum brake pedal travel	High Idle	5495 ± 250 kPa (797 ± 36 psi)
Charge Pump for the Brake Accumulator	Accumulator pressure at low idle	14313 to 15692 kPa (2076 to 22760 psi)
Tires
	Tire pressure	Use the recommendations of the manufacturer.
Hydraulics
Steering System	Standby pressure for the primary steering pump	3900 ± 400 kPa (566 ± 58 psi)
	Steering Pressure at Relief	31000 ± 750 kPa (4496 ± 109 psi)
	Turning time between the left turn stop and the right turn stop	3.7 to 4.6 seconds
	Difference between steering left and steering right	0.3 seconds max
	Gap between the stops of the frame at a full left turn or a full right turn	50 to 80 mm (2 to 3 inch)
	Articulate the machine for 3 degrees and measure the amount of travel after stopping the STIC movement.
Pilot Pressure	Low idle	3450 ± 350 kPa (500 ± 50 psi)
Implement Standby pressure should be 2500 ± 100 kPa (362 ± 14 psi)	High idle Loader bucket at full tilt Main relief pressure for the implement system	31626 ± 700 kPa (4587 ± 102 psi)
	Implement oil temperature	50 to 80°C (122 to 190°F)
	High idle Transmission in neutral Measure the time that is required to raise the empty loader bucket from the ground to the end of the lift cycle.	12 - 13 seconds
	High idle Raise the loader bucket until the lift cylinders are fully extended. Measure the time that is required to move the loader bucket to the dump stop from the full tilt back position.	2.9 - 3.5 seconds
Lift Cylinder	Raise the loader bucket until the lift cylinders are fully extended. Measure the lift cylinder rod drift.	7 mm (.3 inch) max in 1 minute 50-59°C
Tilt Cylinder	Raise the loader bucket until the lift cylinders are fully extended and the loader bucket is level. Measure the tilt cylinder rod drift.	3 mm (.12 inch) max in 1 minute 50-59°C
Leakage		None
Operators Module
Steering Control	Move the STIC to the right.	The machine must articulate to the right.
	Move the STIC to the left.	The machine must articulate to the left.
Transmission Control	Move the transmission control switch through all the different gear positions.	The respective indicator lamp for each gear must come on.
	Depress the reduced rimpull button.	The indicator lamp for the rimpull must be on and LED's above the reduced rimpull switch will be lit according to rimpull settings.
	Depress the lockup clutch switch.	The indicator lamp must turn on.
Parking Brake Control	Engage the parking brake by lifting the interlock tab and press the top of the parking brake switch	Parking brake indicator must be lit
	With the parking brake ON, shift into a FIRST gear with the transmission switch	Transmission must not engage.
	Return the transmission to NEUTRAL, and shift into a SECOND or THIRD gear.	Transmission must engage and the alert indicators must be lit.
Throttle Control	The engine must be running. Push the throttle lock enable switch to the ON position.	The throttle lock lamp must turn on.
	Enable the throttle lock. Depress the accelerator pedal all the way to the stop.	The engine must be running at high idle.
	Release the accelerator pedal.	The pedal must automatically return to the low idle position.
	Depress the accelerator pedal and press the throttle lock enable switch. Release the accelerator pedal.	The engine speed must be held at the same rpm.
	The engine speed must be held by the throttle lock and the accelerator pedal must be released. Press the brake pedal.	The engine speed must return to low idle.
	Press the resume switch for the throttle.	The engine speed must increase, and the engine speed must return to the previously set rpm.
Brake Pedal	Depress the brake pedal.	Applies the brakes to all four wheels. The brake lights at the rear of the machine must turn on.
Left Pedal Control	Partially depress the left brake pedal.	Will reduce the output torque of the torque converter. The torque should be 25% of the lockup torque converter.
	Fully depress the left brake pedal.	Will apply the brakes to all four wheels. The brake lights at the rear of the machine must turn on.
Seat Adjustment Lever	Travel	150 mm (6 inch)
	Height	75 mm (3 inch)
	Suspension	Adjustable
	Back Cushion	Three positions
Seat Belt	Adjust the seat belt to the proper length. Fasten the seat belt.	The seat belt must not slip and the seat belt must not change length.
	Release the seat belt.	The seat belt must unlatch.
Implement Controls	Pull the lift lever rearward past the soft detent and release the lift lever	Bucket must stop smoothly at raise kickout position.
	Push the lift lever forward past the soft detent and release the lift lever	Bucket must stop smoothly at lower kickout position.
	Pull the tilt lever rearward past the soft detent and release the tilt lever	Bucket must stop smoothly at rack kickout position.
	With the bucket near the ground, push the lift lever forward past the soft detent and release the lift lever	Bucket must float down to the ground and float icon will be lit.
Instrument Panel	Turn the key to the ON position.	VIMS does a self-test. The gauges will travel through the entire range of motion.
	Turn the ignition switch and hold the switch in the START position.	The diesel engine must start.
	Release the ignition switch after the engine starts.	The key must return to the ON position.
	Turn the ignition switch to the OFF position.	The engine must stop. All the electrical circuits must de-energize except the instrument panel lights, the running lights, the tail lights, and the lights for the access ladders.
Climate Control	The engine must be stopped and the ignition switch must be ON. Turn the fan speed control dial to the LOW position and the HIGH position.	The fan must be audible at both speeds.
	The engine must be running at normal operating temperature and the valves for the heater lines must be open. Turn the heater control switch ON.	There must be warm air at the dash assembly under the front window wiper blades. There must be warm air on both sides of the seat support.
	Turn the fan speed control dial to the LOW position or the HIGH position.	There must be air flow at the dash assembly under the front window wiper blades. There must be air flow on both sides of the seat support.
Window Wiper Blades	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.
	Depress the wiper switch knobs.	The washers must operate.
	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	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.
	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.	All the flood lamps must be ON.
Auxiliary Flood Lamps	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.
	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 for 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.
Heated Mirrors	Press the heated mirrors button	Mirrors should be heated in 5 minutes
Backlight Dimmer	Press the backlight dimmer button	Keypad button and displays should dim through four settings
Manual Lube	Press the manual lube button	Manual lube cycle should be initiated and no warnings should appear