Field Assembly Of 992G Wheel Loader{7000, 7960} Caterpillar

Wheel Loaders:

992G (S/N: 7HR1-UP)

Wheel Loader:

992G (S/N: AZX1-UP; ADZ1-UP)

Introduction

This publication contains the assembly procedure and the installation information that is required to assemble the above model when the machine is shipped to the field.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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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.

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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

Keep the oil in the hydraulic system at the correct level in order to prevent pump cavitation.

Clean all of the surfaces before you install any parts.

Reference Parts Manual, SEBP2415, S/N:7HR1-UP, Parts Manual, SEBP2989, S/N:ADZ1-UP, Parts Manual, SEBP4013, S/N:AZX1-UP

ReferenceOperation and Maintenance Manual, SEBU7009, S/N:7HR1-UP and ; S/N:ADZ1-UP, Operation and Maintenance Manual, SEBU7978, S/N:AZX1-UP

ReferenceService Manual, SENR1344

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

Illustration 1	g00442303

Components and Weights

Illustration 2	g00443763

• Standard machine (1) without either axle has a weight of 53070 kg (117,000 lb).

• Basic machine (1) with the high lift arm assembly without either axle has a weight of 55338 kg (122,000 lb).

• Rear axle housing (2) with oil has a weight of 7025 kg (15,475 lb).

Illustration 3	g00444041

• Front axle housing (3) with oil 6701 kg (14,760 lb)

• Cab (4) has a weight of 317.8 kg (700 lb).

• ROPS (5) has a weight of 2497 kg (5500 lb).

• Straight Bucket (6) has a weight of 9979 kg (22,000 lb).

Illustration 4	g00443645

• Wheel and tire arrangement (7) has a weight of 3178 kg (7000 lb).

Note: If the rear bumper assembly needs to be installed, use sixteen 8T-5878 Bolts and use sixteen 7X-0616 Hard Washers . Tighten the bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft). The weight of the rear bumper assembly is 2880 kg (6350 lb) with the standard lift arrangement. The weight of the rear bumper assembly is 5516 kg (12160 lb) with the high lift arrangement.

Preparation For Assembly

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Illustration 5	g00444063

1. Park the trailer with the basic machine in the center of a large level area that has a good hard surface. Engage the parking brakes of the truck and place wood blocks between the trailer wheels.

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Illustration 6	g00443923

2. Remove the steps that are located on the left rear of the machine. The steps must be removed in order to install the rear axle assembly and the left rear tire. Set the steps aside for later installation.

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Illustration 7	g00115505

3. Position blocks under the front of the trailer. Lower the front of the trailer onto the blocks. Disconnect the neck of the trailer from the base of the trailer and remove the truck.

4. Remove all the chains and the fasteners that hold the front of the machine on the trailer.

Installation Of The Front Axle

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Illustration 8	g00115507

1. Clean the mounting surfaces for the front axle under the front frame of the machine. Make sure that the machined surface is completely free of dirt.

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Illustration 9	g00115509

2. Clean the mounting surfaces on the front axle housing. Make sure that the machined surface is completely free of dirt.

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Illustration 10	g00115511

3. Use a spreader bar and cables to position the front axle housing (1) under the front frame of the machine.

4. Lift the front axle housing until the dowel pins engage into the holes in the front frame.

5. Use ten 6V-1734 Bolts (2) with twenty 4K-0684 Washers (3) and with ten 3K-9770 Nuts (4) in order to secure each side of the front axle housing to the front frame. Tighten all of the bolts to a torque of 1800 ± 200 N·m (1325 ± 100 lb ft).

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Illustration 11	g00443666

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Illustration 12	g00115516

6. Attach lifting eyes and lifting cables to the lifting eyes on the front frame. Attach the crane to the lifting cables and raise the machine in order to position blocking under the machine. The machine must be high enough to install the tires on the front axle.

Illustration 13	g00115517

Note: Place a block on each side of the tilt cylinder in order to prevent the lifting cables from hitting the hydraulic hoses. Refer to Illustration 13 for positioning of the blocks.

Installation Of The Rear Axle

Note: It is not necessary to perform this procedure if the rear axle is already installed.

1. Clean the mounting surfaces for the rear axle under the rear frame of the machine. Make sure that the machined surface is completely free of dirt.

2. Clean the mounting surfaces on the trunnions of the rear axle housing. Make sure that the machined surface is completely free of dirt.

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Illustration 14	g00268348

3. Position the rear axle assembly (1) under the machine. Use a spreader bar and cables to lift the rear axle assembly into position. Lift the rear axle assembly until the dowel pins engage into the holes in the frame.

4. Use sixteen 1D-4647 Bolts (2) and use sixteen 9M-2828 Hard Washers (3) in order to secure the rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

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Illustration 15	g00268349

5. Use six 2J-8348 Bolts (4) and use six 9M-2828 Hard Washers (3) in order to secure the front rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

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Illustration 16	g00268350

6. Place a wood block between the axle housing and the rear main frame on both sides of the machine. The wood blocks will prevent the rear axle from oscillating while you are working near the rear axle.

Installation Of The Tires

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Illustration 17	g00115530

1. Use a hoist and use a sling in order to install the front tires. The valve stem should be facing outward when the tires are installed. Install a 9X-8898 Bolt with a 5P-8250 Washer in several locations in order to hold the tire and rim assembly in place.

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Illustration 18	g00115531

2. Install the remainder of the 9X-8898 Bolts (1) with 5P-8250 Washers (2) in the front rim assembly. Tighten all of the bolts to a torque of 1152 N·m (850 lb ft).

3. Follow the procedure in Step 1 and Step 2 in order to install both rear tires on the machine.

4. After the tires have been installed on the machine, remove the truck trailer.

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Illustration 19	g00115535

5. Reinstall the steps on the left rear of the machine.

Installation Of The Cab

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Illustration 20	g00115545

1. Install 117-7607 Seat Suspension (1) in the cab with four 8T-0722 Bolts (2) and with four 8T-4121 Washers (3) .

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Illustration 21	g00115547

2. Slide seat (4) into position on seat suspension (1) .

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Illustration 22	g00117913

Note: Remove the instrument panel and lay the instrument panel on the floor of the cab. Removing the instrument panel will prevent the instrument panel from being hit and being damaged when the top of the cab is lowered into position.

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Illustration 23	g00444024

3. Attach a chain to the four brackets that are located on the top of the cab.

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Illustration 24	g00270068

4. Ensure that 4E-6508 Seal (E) is located on the bottom portion of the cab. Ensure that 4E-6509 Seal (F) is located on the bottom portion of the cab. Ensure that 4E-6510 Seal (G) is located on the bottom portion of the cab.

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Illustration 25	g00117917

5. Lift the top portion of the cab into position over the bottom portion of the cab. Slowly lower the top of the cab into position. There are three dowel pins (A) on the lower portion of the cab which are used to line up the top portion of the cab with the bottom portion of the cab.

   Note: The top portion of the cab will need to be guided into position onto the bottom portion of the cab.

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Illustration 26	g00444037
Front of the cab

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Illustration 27	g00443944
Rear of the cab

6. Secure the top portion of the cab with twenty 8T-4136 Bolts (5) and with twenty 8T-4223 Hard Washers (6) that are located around the platform.

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Illustration 28	g00444035

7. Connect the wiring harness (7) between the top portion of the cab and the bottom portion of the cab. Connect the tube for the washer fluid to the front wiper motor (8) .

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Illustration 29	g00444125

8. Reinstall the front instrument panel with four 9X-2046 Screws (9) .

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Illustration 30	g00443910

9. Install 090-4808 Seal (10) around the vent of the existing air duct (B). Install 123-8721 Duct (11) over the vent of the existing air duct (B) .

10. Install 090-4808 Seal (10) around the top opening of the 123-8721 Duct (11) .

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Illustration 31	g00443589

11. Install foam inserts on the center section of 123-8720 Duct (12) .

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Illustration 32	g00117935

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Illustration 33	g00443623

12. Install 123-8720 Duct (12) over the front instrument panel and over the 123-8721 Duct (11). Secure the duct in place with four 8T-4191 Bolts (15) and with four 8T-4121 Washers (16). The bolts are located under the louvers on each side of the front instrument panel.

13. Snap all louvers (13) into position. Secure the louvers with 104-2091 Flat Head Screws (14) .

    Note: The three louvers that are located in location (C) do not require screws.

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Illustration 34	g00444066

14. Install 4E-9640 Handle (17) through the holes in the top of 123-8720 Duct (12) .

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Illustration 35	g00123256

15. Secure 4E-9640 Handle from the bottom side of the front dash with two 8T-4183 Bolts (18) and two 8T-4223 Hard Washers (19) .

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Illustration 36	g00444028

16. Install 123-8723 Cover (20) over the right side dash panel. Secure the cover with 9X-2042 Screws (21) .

    Note: Install a 9X-2042 Screw and a 5C-2890 Nut in location (D) in order to plug the hole in the 123-8723 Cover (20) .

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Illustration 37	g00443843

17. Connect the wire harness (22) and the tube for the washer fluid to the rear wiper motor (23) .

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Illustration 38	g00442363

18. Install 4E-7205 Seal (24) around the bottom of 123-8722 Duct (25) .

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Illustration 39	g00443443

19. Install the 123-8722 Duct (25) behind the seat. Secure the duct with 8T-4189 Bolts (26) and 8T-4222 Washers (27) .

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Illustration 40	g00117945

20. Install 9X-8216 Air Filter (28) in the opening of the 123-8722 Duct (25) .

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Illustration 41	g00117985

21. Install 4E-7204 Cover Assembly (29) over the 9X-8216 Air Filter .

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Illustration 42	g00444027

22. Install 123-8725 Insulation (30) over the right rear inside post of the cab.

23. Snap the louvers (31) into position in 123-8725 Insulation .

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Illustration 43	g00443863

24. Install 123-8724 Insulation (32) over the left rear inside post of the cab.

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Illustration 44	g00444129

25. Install 6V-8928 Coat Hook (34) with one 9X-2042 Screw (33).

26. Install 3E-6389 Dome Lamp (35) onto 123-8724 Insulation (32) with three 9X-1046 Screws .

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Illustration 45	g00444036
Guide rod for the front sun screen.

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Illustration 46	g00443446
Guide rod for the rear sun screen.

27. Insert the post for the guide rod for the sun screens. 8Y-6396 Guide Rod (36) is longer than 8Y-6397 Guide Rod (37). Use 8Y-6396 Guide Rod (36) for the front sun screen. Use 8Y-6397 Guide Rod (37) for the rear sun screen. Place the lower end of the guide rod through the lower bracket on the sun screen. Place the lower end of the guide rod through the bracket on the duct. Snap the top into the end of the sun screen.

    Note: There is a cord on the right side of each sun screen. The rod needs to be inserted through clamp (38) in order to keep the cord from swinging during machine operation.

Installation Of Steps and Handholds

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Illustration 47	g00443320

1. Install 135-8640 Step Group (1) on the left rear side of the machine. Use four 8T-4194 Bolts (2) with four 5P-1076 Hard Washers (3) to attach the step group.

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Illustration 48	g00444040

2. Install 4E-8852 Handle (4) on the left rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (7).

3. Install 4E-8892 Handle (5) on the left rear bumper. Secure the handle with four 8T-4194 Bolts (8) and four 5P-1076 Hard Washers (7) .

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Illustration 49	g00444103

4. Install 135-8640 Step Group (1) on the right rear side of the machine. Use four 8T-4194 Bolts (2) with four 5P-1076 Hard Washers (3) to attach the step group.

5. Install 4E-8852 Handle (4) on the right rear bumper. Secure the handle with four 8T-4194 Bolts (8) and four 5P-1076 Hard Washers (7) .

6. Install 4E-8892 Handle (5) on the right rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (7) .

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Illustration 50	g00443448

7. Install 112-4557 Handhold Assembly (9) on the step assembly. Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

8. Install 122-5967 Handhold Assembly (10). Secure the handhold assembly with four 8T-4183 Bolts (13) and four 5P-1076 Hard Washers (14) .

9. Connect 112-4557 Handhold Assembly (9) to the 122-5967 Handhold Assembly (10). Connect the handholds with one 8T-4195 Bolt (15) and one 7X-7729 Washer (16) .

10. Install 116-0059 Handhold Assembly (11). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

11. Connect 116-0059 Handhold Assembly (11) to the 122-5967 Handhold Assembly (10). Connect the handholds with one 8T-4195 Bolt (15) and one 7X-7729 Washer (16) .

12. Install 116-0060 Handhold Assembly (12). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

13. Connect 116-0060 Handhold Assembly (12) to the 116-0059 Handhold Assembly (11). Connect the handholds with one 8T-4195 Bolt (15) and one 7X-7729 Washer (16) .

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Illustration 51	g00444030

14. Install 116-0063 Handhold Assembly (17). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

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Illustration 52	g00443909

15. Install 116-0062 Handhold Assembly (18). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

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Illustration 53	g00443908

16. Install 116-0064 Handhold Assembly (19). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

17. Connect 116-0064 Handhold Assembly (19) to the 116-0062 Handhold Assembly (18). Connect the handholds with one 8T-4195 Bolt (15) and one 7X-7729 Washer (16) .

18. Install 116-0061 Handhold Assembly (20). Secure the handhold assembly with six 8T-4183 Bolts (13) and six 5P-1076 Hard Washers (14) .

19. Install 112-7300 Ladder Assembly (21) on the right side of the machine. Secure the ladder assembly with four 8T-4183 Bolts (13) and four 5P-1076 Hard Washers (14) .

Installation Of The ROPS

Illustration 54	g00443945

Illustration 55	g00444065

1. Remove 113-6026 Cover Assembly (1) from the right side of the platform and remove 113-6027 Cover Assembly (2) from the left side of the platform. These cover assemblies need to be removed in order to install the ROPS.

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Illustration 56	g00443235

2. Install three lifting eyes onto the top of the ROPS. Use the three holes that are provided in the top of the ROPS. Attach a crane to the ROPS.

   Note: Protect the wiring harnesses that are located on the ROPS when the ROPS is being installed.

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Illustration 57	g00444133

3. Clean the ROPS mounting surface that is on the machine. Clean the ROPS mounting surface that is on the ROPS.

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Illustration 58	g00443649

4. Use a crane to lift the ROPS into position over the top of the cab.

   Note: The ROPS will need to be guided into position on the machine.

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Illustration 59	g00444034

Note: Apply oil to all the threads on the bolts for the ROPS before installation. Failure to apply oil can result in improper bolt torque.

5. Secure the ROPS with twenty 8C-3236 Bolts (3) and twenty 3S-7023 Washers (4) on each side of the ROPS. Tighten the bolts to a torque of 1600 ± 200 N·m (1200 ± 150 lb ft).

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Illustration 60	g00444026

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Illustration 61	g00443943

6. Install 113-6026 Cover Assembly (1) on the right side of the platform. Install 113-6027 Cover Assembly (2) on the left side of the platform.

Installation Of The Lights, Mirrors, Door, Exhaust Stacks and Antennas

Illustration 62	g00443447

1. Place 3E-6516 Film (1) onto 128-6063 Cover (2) .

   Note: Wet the back side of the film before placing the film on any surface. Wetting the film will enable the film to be moved after the film has been placed on the surface. The water that is behind the film must be removed. Apply pressure to the film in order to remove the water.

2. Install 128-6063 Cover (2) onto the top rear of the ROPS. Install 4E-9625 Bracket Assembly (3) onto the top rear of the ROPS. Install 9U-0833 Bracket Assembly (4) onto the top rear of the ROPS. Use four 8T-4137 Bolts (5) .

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Illustration 63	g00443823

3. Connect the wire harnesses to 9X-6774 Floodlight (6). Mount one floodlight to each bracket assembly with a 8T-4137 Bolt (5). Torque bolt (5) to 12 ± 4 N·m (106 ± 35 lb in).

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Illustration 64	g00444039

4. Place 3E-6514 Film (7) onto 9U-3663 Plate Assembly (8) .

   Note: Wet the back side of the film before placing the film on any surface. Wetting the film will enable the film to be moved after the film has been placed on the surface. The water that is behind the film must be removed. Apply pressure to the film in order to remove the water.

5. Mount 9U-3663 Plate Assembly (8) onto the front of the ROPS with five 6V-3822 Bolts (9) and five 6V-5839 Washers (10) .

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Illustration 65	g00443644

6. Connect the wire harness to each 9X-6774 Floodlight (6). Mount one floodlight on the left front corner of the ROPS. Mount one floodlight on the right front corner of the ROPS. Mount each floodlight with one 8T-4137 Bolt (5). Torque bolt (5) to 12 ± 4 N·m (106 ± 35 lb in).

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Illustration 66	g00443785

7. Install 9U-2670 Handhold (11) on the upper right front corner of the cab with two 8T-4133 Nuts (13) and with two 8T-4121 Washers (14) .

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Illustration 67	g00444038

8. Install 9U-1301 Handhold (12) on the upper left front corner of the cab with two 8T-4133 Nuts (13) and two 8T-4121 Washers (14) .

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Illustration 68	g00443523

9. Install 126-6561 Bracket Assembly (15) onto the right side of the ROPS and install 126-6562 Bracket Assembly onto the left side of the ROPS. Secure each bracket assembly with four 8T-4956 Bolts (16) and four 5P-1076 Hard Washers (17) .

10. Mount one 5P-6879 Mirror (18) on each bracket assembly. Secure each mirror with two 8T-4136 Bolts (19), with two 7X-7729 Washers (20) and with two 6V-7744 Locknuts (21) .

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Illustration 69	g00443311

11. Install 128-6758 Step Assembly (22) on the lower right front of the cab. Install 128-6757 Step Assembly on the lower left front of the cab. Secure each step assembly with two 8T-4195 Bolts (23) and two 8T-4121 Washers (14) .

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Illustration 70	g00443903

12. Install the cab door (24). Secure the cab door with six 8T-4196 Bolts (25) and six 8T-4121 Washers (14). Use the following procedure in order to adjust the door latch.

    1. Close the cab door. Locate the striker in the cab assembly so that the following conditions exist.
       • The striker is centered vertically in the jaws of the latch.

       • The striker smoothly engages the jaws of the latch.

       • The striker does not guide the door upward.

       • The striker does not guide the door downward.

    2. Check for interference between the head of the striker and the jaws. Check for interference between the head of the striker and the latch. Adjust the striker by adding shims or by removing shims. Add or remove shims only if it is necessary.

    3. Check the secondary latch position and the primary latch position. In the primary latch position, the door is completely closed, and the door is completely latched. In the secondary latch position, the door is latched, but the jaws are not in the primary latch position.

    4. If the seal is restricting the normally closed position of the door, loosen the striker on the post of the door. If an incorrect position of the striker is restricting the normally closed position of the door, loosen the striker on the post of the door. Torque the bolts.

       Note: Adjustment of the hinge may be required in order to achieve the primary latch position. Adjustment of the hinge may be required in order to achieve a correct seal between the door and the cab. Add shims or remove shims, if necessary. The door should be flush with sheet metal of the cab.

       Note: It is possible to adjust the door so that the door is fully closed against the seal with the latch in the secondary position. Increased effort will need to be applied to the door handle if there is excessive pressure between the door and the seal.

    5. The latches are coated with dry lubricant. Wet lubricant is not recommended for use on the latches. Wet lubricant causes dust to build up on the latches. When lubrication is necessary, use a dry lubricant in order to maintain smooth operation.

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Illustration 71	g00444067

13. Attach bracket (26) to the cab door. The bracket is located on the spring of the cab door. Secure the bracket with two 8T-4137 Bolts (5) and two 8T-4121 Washers (14) .

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Illustration 72	g00444033

14. Install two short exhaust stacks (27). Tighten clamp bolt (28) in order to secure the exhaust stacks.

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Illustration 73	g00443229

15. Position the taller exhaust stacks (29) over the shorter exhaust stacks. Secure the tall exhaust stacks to the top of the hood. Use four bolts (30) on each exhaust stack.

16. Install precleaner assemblies (31) over the inlet openings. Tighten the clamp bolt on each precleaner.

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Illustration 74	g00467057
Front view of ROPS

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Illustration 75	g00467058

17. Attach 9U-2330 Antenna Mount (33) to the ROPS. Attach 9U-2331 Antenna Assembly (32) to 9U-2330 Antenna Mount (33) .

18. Attach 9U-2330 Antenna Mount (35) to the ROPS. Attach 9U-2332 Citizens Band Antenna Assembly (34) to 9U-2330 Antenna Mount (35) .

Installation Of Front Drive Shaft and Front Brake Oil Lines

Illustration 76	g00118076

1. Connect front drive shaft (1) to the front differential. Install four bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

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Illustration 77	g00118133

2. Connect one end of 125-3541 Tube Assembly (3) to the left side of 134-5247 Block (4). 125-3541 Tube Assembly (3) is the return line for the left brake oil cooler.

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Illustration 78	g00118134

3. Connect one end of 118-5041 Tube Assembly (left service brake oil line) (5) to 115-2516 Block (6).

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Illustration 79	g00118139

4. Connect the opposite end of 125-3541 Tube Assembly (left brake oil cooler line) (3) to the left brake housing (7). Connect the opposite end of 118-5041 Tube Assembly (left service brake oil line) (5) to the left brake housing (7) .

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Illustration 80	g00118140

5. Connect oil suction line (8) to the differential.

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Illustration 81	g00118141

6. Connect one end of 125-3542 Tube Assembly (9) (right brake oil cooler line) to the right side of 134-5247 Hydraulic Block Group (4) .

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Illustration 82	g00118142

7. Connect one end of 117-6727 Tube Assembly (right service brake oil line) (11) to 115-2516 Block (6) .

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Illustration 83	g00118144

8. Connect the opposite end of 125-3542 Tube Assembly (right brake oil cooler line) (9) to right brake housing (12). Connect the opposite end of 117-6727 Tube Assembly (right service brake oil line) (11) to right brake housing (12) .

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Illustration 84	g00118167

9. Connect one end of 125-5838 Tube Assembly (return line of differential oil cooler) (13) to the differential. Connect the opposite end of 125-5838 Tube Assembly to 134-5247 Block (4) .

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Illustration 85	g00118169

10. Connect the harness connector (14) and secure the connector clip to the differential.

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Illustration 86	g00118171

11. Secure all lines with clips to any available bosses.

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Illustration 87	g00118172

12. Install 124-1875 Guard Assembly over the brake lines on the right side of the front axle. Install 124-2472 Guard Assembly over the brake lines on the left side of the front axle. Use 8T-4179 Bolts and 8T-4223 Hard Washers for installation.

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Illustration 88	g00118178

13. Connect service brake oil line (15) to hydraulic block (16). Hydraulic block (16) is located inside the front frame.

    Note: Purge the air from the brake system before you operate the machine.

Installation Of Rear Drive Shaft and Rear Brake Oil Lines

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Illustration 89	g00268356

1. Connect the rear drive shaft (1) to the rear differential. Install four bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

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Illustration 90	g00268354

2. Connect temperature sensor harness (5) .

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Illustration 91	g00268358

3. Connect 116-6764 Hose Assembly (service brake oil line) (6) to 115-2516 Block (7) .

4. Connect grease tube assembly (4) to the front trunnion support.

5. Connect one end of 117-6725 Tube Assembly (right service brake line) (8) to 115-2516 Block (7) .

6. Connect one end of 117-6726 Tube Assembly (left service brake line) (9) to 115-2516 Block (7) .

7. Connect 118-0630 Tube Assembly (oil return line) (10) to the axle housing.

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Illustration 92	g00268360

8. Connect 118-0631 Tube Assembly (suction line for axle oil) (11) to the bottom of the axle housing.

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Illustration 93	g00268362

9. Secure 118-0630 Tube Assembly (oil return line) (10) and secure 118-0631 Tube Assembly (suction line for axle oil) (11). Secure the tube assemblies with 8C-3174 Grommet (12) that is located above the axle housing.

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Illustration 94	g00268365

10. Connect 125-3538 Tube Assembly (left brake oil cooler line) (17) to 134-5248 Hydraulic Block Group (13) .

11. Connect 125-3540 Tube Assembly (right brake oil cooler line) (14) to the opposite side of 134-5248 Hydraulic Block Group (13) .

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Illustration 95	g00268890

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Illustration 96	g00268993

12. Connect 117-9372 Hose Assembly (return line for axle oil) (15) to 134-5248 Hydraulic Block Group (13) .

13. Connect the opposite end of 118-0630 Tube Assembly (oil return line) (10) to 134-5248 Hydraulic Block Group (13) .

14. Connect suction line (16) for the axle to the opposite end of 118-0631 Tube Assembly (suction line for axle oil) (11) .

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Illustration 97	g00269124

15. Connect the opposite end of 125-3538 Tube Assembly (left brake oil cooler line) (17) to the left rear brake housing. Connect the opposite end of 117-6726 Tube Assembly (left service brake line) (9) to the left rear brake housing.

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Illustration 98	g00269148

16. Connect the opposite ends of 125-3540 Tube Assembly (right brake oil cooler line) (14) and 117-6725 Tube Assembly (right service brake line) (7) to the right brake housing.

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Illustration 99	g00269386

17. Connect the grease tube assembly to the rear trunnion support.

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Illustration 100	g00269479

18. Install 124-1875 Guard Assembly over the brake lines on the right side of the rear axle. Install 124-2472 Guard Assembly over the brake lines on the left side of the rear axle. Use 8T-4179 Bolts and 8T-4223 Hard Washers for installation.

Installation Of The Bucket

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NOTICE
Do Not raise the boom without the bucket and boom tilt link installed. Tilt cylinder rod damage can occur if the boom is raised too high without the bucket completely installed.

Illustration 101	g00437623

1. Position the bucket on the ground in front of the machine. Remove the covers from each side of the bucket pin bores.

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Illustration 102	g00118180

2. Thoroughly clean the pin bore of the bucket. Apply 5P-3931 Anti-Seize Compound to the pin bore of the bucket.

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Illustration 103	g00558406

3. Lubricate the bearing bore of the boom with 8T-9582 SAE 80W90 Oil .

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Illustration 104	g00363278
155-5516 Ring

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Illustration 105	g00363455
155-5517 Plunger

4. Use the tools that are described in Table 1 in order to install the seals into the collars.
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   Table 1

   Tools Needed For Pins with a Diameter of 180 mm (7.1 inch)
   Qty	Part Number	Description
   1	155-5516	Ring
   1	155-5517	Plunger

   Note: Seals that are poorly assembled are the primary reason for leakage and for the seizing of pins.

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Illustration 106	g00337272
(1) Compression ring. (2) Seal. (3) 155-5516 Ring . (4) 155-5516 Ring with seal and compression ring.

5. Lubricate compression ring (1), seal (2), and 155-5516 Ring (3) with 8T-9582 SAE 80W90 Oil .

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Illustration 107	g00338472
(4) 155-5516 Ring with seal and compression ring.

6. Install compression ring (1) and seal (2) into 155-5516 Ring (3). See Illustration 106 and Illustration 107.

   Note: The seal and the compression ring will remain in 115-5516 Ring when the seal assembly is assembled correctly.

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Illustration 108	g00337372
(4) 155-5516 Ring with seal and compression ring. (5) 155-5517 Plunger .

7. Position 155-5516 Ring with seal and compression ring (4) onto 155-5517 Plunger (5) .

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Illustration 109	g00338532
(6) Correct assembly of 155-5516 Ring and 155-5517 Plunger .

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Illustration 110	g00337414
(6) 155-5517 Plunger with 155-5516 Ring . (7) Collar .

8. Lubricate the groove of collar (7) with 8T-9582 SAE 80W90 Oil . Insert assembly (6) into the bore of collar (7). The fit will be loose, as the 155-5517 Plunger acts as a guide to guarantee proper alignment.
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   Illustration 111	g00363736
   (6) 155-5517 Plunger with 155-5516 Ring . (7) Collar .

   1. Evenly apply pressure around the edges of 155-5517 Plunger (6) until the seal is inserted into the groove of collar (7) .

9. Remove assembly (6) from collar (7).

   Note: A properly installed seal will remain in the seal groove of the collar.

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Illustration 112	g00338534
Correct seal assembly installation in the collar.

10. Repeat Steps 5 through 9 for the installation of the remaining seal assemblies.

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Illustration 113	g00553729

11. Install collar (1) into the bores of the bucket.

    Note: Ensure that collar (1) is recessed from the hinged plates. See Illustration 113. The collar should be recessed when the bucket is lowered into position over the boom in order to keep the seals from being damaged. Damage will occur to the face of the seals if the collars are not recessed from the hinged plates.

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Illustration 114	g00553738

12. Raise the boom off the ground. Place a hydraulic jack or blocking under the bottom of the boom in order to keep the boom raised approximately 0.3 m (1 ft) off the ground.

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Illustration 115	g00554722

13. Fasten a hoist and suitable lifting chains to the bucket. See Illustration 115 for the proper way to attach the chains to the bucket. The weight of the bucket is 9940 kg (21900 lb). Lift the bucket into position and align the pin bores with the bearing bores.

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Illustration 116	g00437863

14. Coat the bucket pin (2), the inner surface of the bearings, and the inner surfaces of the collars with 8T-9582 SAE 80W90 Oil before installing the pin.

15. Use a hoist and a suitable lifting sling in order to install bucket pin (2). The weight of bucket pin (2) is 209 kg (460 lb).

    Note: Do not use a hammer or other force except for pushing by hand in order to install the bucket pin. Excessive vibration can cause a seal to leave the seal groove. The seal will be crushed and the link pin joint will leak.

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Illustration 117	g00437865

16. Ensure that the flag on bucket pin (2) is positioned in the flag retainer that is welded to the bucket. Install retainer plate (4) with four bolts (3). Tighten the four bolts (3) to a torque of 240 ± 40 N·m (177 ± 29 lb ft).

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Illustration 118	g00437923

17. Install O-ring seal (5) in the groove of bucket pin (2) .

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Illustration 119	g00553805

18. Align the dowels on 145-5007 Plate (6) with the dowel holes in the end of the bucket pin. The two fill ports in plate assembly (6) should be located on the upper portion of the pin diameter. Secure plate assembly (6) to the bucket pin with one bolt (7) and the washer. Tighten bolt (7) to a torque of 2700 ± 300 N·m (1990 ± 220 lb ft).

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Illustration 120	g00352989

19. Pressure test the bucket pin before oil is added by following Steps 19.a through 19.e.
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    Table 2

    Parts Needed
    Item	Qty	Part Number	Description
    1	1	8T-0854	Pressure Gauge
    2	1	006-0210	Tee
    3	1	008-0728	Nipple
    4	1	1S-8937	Needle Valve
    5	1	N/A	Air Chuck
    6	1	1Y-7452	Nipple
    7	1	030-8370	Adapter
    8	1	3K-0360	Seal
    9	1	5P-1838	Adapter

    1. Turn off the machine.

    2. Assemble the parts in Table 2 according to Illustration 120.
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    Illustration 121	g00553864

    3. Install the assembled parts onto the boom. See Illustration 121.

    4. Apply 415 kPa (60 psi) to 1035 kPa (150 psi)of air pressure to the fill port hole of the pin joint. Use 1S-8937 Needle Valve (4) in order to apply the pressure.

    5. Monitor the pressure for five minutes with 8T-0854 Pressure Gauge (1). The pressure should not drop at all. A seal has been rolled or a seal has been crushed if the pressure drops. The pin joint must be disassembled and the pin joint must be repaired if the seal is rolled or if the seal is crushed.

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Illustration 122	g00438465

20. Remove the oil level/fill plug that is located in the fill port in Illustration 122.

21. Fill the pin joint with 7.5 ± 0.5 L (2.0 ± 0.1 gal) of 80W90 EP Gear Oil.

    Note: Do not overfill the pin joint. Oil leaks and excessive pressures in the pin joint can be caused by overfilling the pin joint.

22. Clean the fill port plug and install the fill port plug.

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Illustration 123	g00437929

23. Use a hoist and a suitable lifting device to raise bucket tilt link (8) into position. Place cribbing and a 8T-5255 Hydraulic Jack between boom (9) and bucket tilt link (8). Do not remove the hoist and do not remove the hydraulic jack until the pin for the bucket tilt link is installed.

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Illustration 124	g00553870

24. Install collars (1) in the bores of the bucket.

    Note: The upper bucket pin is designed for grease. The upper bucket pin does not require maintenance free linkage seals. Install the collars (1) without seals.

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Illustration 125	g00438003

25. Remove the protective coating from pin (10) .

26. Lubricate pin (10) and the bearing bores in the tilt link with lubricant.

27. Use a hoist and a suitable lifting device in order to install pin (10) .

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Illustration 126	g00438183

28. Ensure that the flag on pin (10) is positioned in the slot on the bucket. Install retainer plate (11) with four bolts (12). Tighten four bolts (12) to a torque of 240 ± 40 N·m (177 ± 29 lb ft).

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Illustration 127	g00553878

29. Align dowels in 161-8990 Plate (14) with dowel holes in the end of the bucket pin. Secure the plate assembly (14) to the bucket pin with one bolt (15) and one washer. Tighten the bolt to a torque of 2700 ± 300 N·m (1990 ± 220 lb ft).

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Illustration 128	g00553927

30. Pump grease into the two zerk grease fittings on the underside of the tilt link that are shown in Illustration 128.

31. Stop pumping when grease starts to push out past the seals.

32. Check the upper rack stop and check the lower rack stops for alignment. Check the dump stop for proper alignment.

    ReferenceRefer to the sections ""Alignment Procedure of the Rack Stops" " and ""Alignment Procedure of the Dump Stops" " in this manual.

33. Calibrate the position sensor for the tilt linkage.

    ReferenceRefer to the sections ""Position Sensor (Tilt Linkage) - Set" " and ""Position Sensor (Tilt Linkage) - Calibrate" " in this manual.

Alignment Procedure of the Rack Stops

The alignment procedures enable the upper rack stops and the lower rack stops to hit at the same time. The rack stops will hit on the top, on the bottom, and on both sides simultaneously. Use the following procedures in order to check the alignment and align the stops, if necessary.

Build Up and Alignment of the Upper Rack Stop

Note: The bucket must be installed on the machine before checking for proper alignment.

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Illustration 129	g00432145
(1) Upper rack stop. (2) Direction of welds. (3) Locations of the radius.

Note: Illustration 129 is intended for reference only. The boom in the illustration is shown alone in order to ensure clarity.

1. Tilt the bucket backward against the upper rack stop and check for uneven contact between the bucket tilt link and the boom.

   Note: Do not use additional hydraulic force in order to cause the bucket tilt link to contact the stops on both sides of the boom. Take all measurements at initial contact between the bucket and the boom. Taking measurements at initial contact will prevent twisting.

2. Build up the upper rack stops, as needed. Follow Steps 3 through 9 in order to build up the upper rack stops.

   Note: If the left and right stops touch evenly at this point, stop here and inspect the alignment of the lower rack stops.

3. Grind the wear surface of rack stop (1). Remove any excess material (mushrooming) that was caused by impact.

   Note: Avoid high grinding pressures that may cause burning and discoloration.

4. Preheat upper rack stop (1) to 121°C (250°F).
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   Table 3

   Recommended Welding Processes and Filler Metals
   Welding Process	AWS Specification	Welding Electrode
   SMAW (Stick Welding)	A5.1	E7018 or Equivalent
   GMAW (MIG Welding)	A5.18	ER70S-3 or Equivalent
   FCAW (Gas Shielding)	A5.20	E70T-1 (1), E71T-1 (2)

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   ( 1 )	Use E70T-1 electrodes for the welding of horizontal positions and flat positions.
   ( 2 )	Use E71T-1 electrode for the welding of all positions.

5. Build up the surface of upper rack stop (1). Build up the surface with one of the processes and with one of the filler metals that are listed in Table 3.

6. Weld in direction (2). The weld should be parallel to the axis of the boom. Ensure that the width of each weld does not exceed 9.53 mm (.375 inch).

7. Overlap each weld 3.18 mm (.125 inch). Blend each weld with the other weld beads.

   Note: Welds should be free of crater cracks, slag inclusions, porosity, or any other visible discontinuities.

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Illustration 130	g00429862
(1) Upper rack stop. (3) Locations of the radius. (A) 3.18 mm (.125 inch).

8. Clean the weld after each pass. Ensure that the finished weld is no less than 3.18 mm (.125 inch) (A) above rack stop (1) .

   Note: Do not weld the rack stop at locations of the radius (3) .

9. Grind the surface of the weld smooth and grind the surface of the weld straight. Do not grind the weld below the surface of rack stop (1) .

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Illustration 131	g00432678
(1) Upper rack stop.

10. Verify that uniform contact exists between the tilt link and upper rack stop (1). Ensure that uniform contact exists on all sides of rack stop (1) .

    Note: The upper rack stop and the lower rack stops should make contact at the same time. Do not use hydraulic pressures in order to force the stops to touch at the same time. Check for even contact at initial contact only in order to prevent twisting.

Build Up and Alignment of the Lower Rack Stop

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Illustration 132	g00429919
(4) Direction of welds. (5) Lower rack stops.

1. Tilt the bucket fully backward. Check for uneven contact between the bucket and the lower rack stops.

   Note: Do not use additional hydraulic force in order to cause the tilt link to contact the lower rack stops on both sides. Take all measurements at initial contact between the tilt link and the boom in order to prevent twisting.

2. Build up the lower rack stops, as needed. Follow Steps 3 through 9 in order to build up the lower rack stop.

   Note: If there is even contact between the tilt link and the lower rack stops, and the upper stops are also aligned, proceed to the ""Alignment Procedure of the Dump Stops" ".

3. Grind the wear surface of rack stop (5). Remove any excess material (mushrooming) that was caused by impact.

   Note: Avoid high grinding pressures that may cause burning and discoloration.

4. Preheat lower rack stops (5) to 121°C (250°F).

5. Build up the surface of lower rack stop (5). Build up the surface with one of the processes and with one of the filler metals that are listed in Table 3.

6. Weld in direction (4). The weld should be parallel to the axis of the boom. Ensure that each weld does not exceed a width of 9.53 mm (.375 inch).

7. Overlap each weld 3.18 mm (.125 inch). Blend each weld with the other weld beads.

   Note: Welds should be free of crater cracks, slag inclusions, porosity, or any other visible discontinuity.

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Illustration 133	g00429998
Lower rack stops. (6) Finished welded surfaces. (B) 3.18 mm (.125 inch).

8. Clean the weld after each pass. Ensure that the finished weld is no less than 3.18 mm (.125 inch) (B) above the surface of the casting.

9. Grind the surface of weld (6) smooth and grind the surface of weld (6) straight in order to provide uniform contact on each rack stop (5) .

10. Verify that uniform contact exists between the tilt link and each lower rack stop (5). There must also be uniform contact on all sides of each rack stop.

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Illustration 134	g00430118
(7) Corner of lower rack stop.

11. Grind all four corners (7) of each stop in order to form a smooth radius at each corner.

    Note: The upper rack stop and the lower rack stops should make contact simultaneously. The rack stops will hit on the top, on the bottom, and on both sides simultaneously. Build up the stops and recheck the alignment again, if the contact is uneven.

Alignment Procedure of the Dump Stops

The boom may crack or the bucket may crack if the boom dump stop partially contacts the bucket dump stop. The following steps describe the correct procedure in order to correct the problem.

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Illustration 135	g00473153
Boom dump stop (bottom view of boom) .

1. Clean the boom and clean the bucket dump stops.

2. Apply a light coat of grease to the boom dump stop. The grease will help determine the amount of contact that is being made between the boom dump stop and the bucket dump stop.

3. Operate the machine until the dump stop on the bucket and the dump stop on the boom contact each other. Tilt the bucket backward partially in order to inspect the alignment.

4. Inspect the dump stops on the bucket and on the boom in order to determine the amount of contact that is being made. If even contact is being made across the dump stop no further action is required. If only partial contact or uneven contact is being made, perform the following steps.

5. Remove the high spots on the boom dump stop with a hand grinder.

6. Repeat Steps 2 through 4 until even contact between the dump stop on the bucket and the dump stop on the boom is being made.

   Note: It may be necessary to trim the edges of the boom dump stop in order to prevent hitting the weld on the bucket dump stop. Contact should be 6.4 mm (0.25 inch) from the weld beads on the bucket.

Position Sensor (Tilt Linkage) - Calibrate

Calibration of the tilt linkage position sensor must be performed before this machine can be put into service. The ECM must be programmed with the minimum and maximum travel points of the bucket.

Note: The messages that appear on the diagnostic message screen may differ from the messages that are listed in this procedure.

ReferenceRefer to the section ""Glossary of Calibration Messages" " in this manual for more information on messages that appear on the diagnostic message screen.

1. Engage the parking brake.

2. If the machine is equipped with ride control, move the ride control switch to the OFF position.

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

4. The area must be clear so that the bucket can be fully raised and fully lowered.

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Illustration 136	g00284487
Right Console (1) Keypad.

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Illustration 137	g00286975
Front Dash (2) Diagnostic message screen.

5. Press the "OK" key on keypad (1) repeatedly in order to clear any error messages that are flashing on the display. Press the "OK" key on keypad (1) repeatedly until the hour meter appears on diagnostic message screen (2) .

6. On the keypad, enter "SERV (7378)" and then press the "OK" key. Press the ">" key until "TILT LINK SNSR - CAL" is displayed on the bottom line of the diagnostic message screen. Press "OK" twice in order to start the calibration.

Note: All calibrations must be performed while the engine is running at high idle.

7. Follow the instructions on the diagnostic message screen in order to complete the procedure. Place the bucket in the position according to the message on the diagnostic message screen.

8. There are two methods of calibrating the dump position. Follow one of the options below when the command "TILT BKT FWD FULLY" appears on the screen.

   1. Soft Dump Calibration - This method should be used if the customer has loose material that does not stick to the bucket. This method provides longer structural life for the boom, the bucket, and the hitch.
      • Move the tilt lever to the FULL DUMP position.

      • Release the lever just as the bucket hits the boom.

      • DO NOT build up hydraulic pressure in the tilt cylinder.

      • Press "OK" when you are done.

   2. Hard Dump Calibration - This method should only be used if the customer has a problem with material that sticks to the bucket.
      • Move the tilt lever to the FULL DUMP position.

      • Continue to hold the lever after the bucket hits the boom.

      • Build hydraulic pressure.

      • As you are holding the lever in the FULL DUMP position, press the "OK" key.

9. If the calibration passes, a message will read "CALIBRATION COMPLETED OK".

10. If the calibration fails, return to the "LINKAGE SNSRS-SET" routine. The computer will calculate a new target value according to the cause of the failure of the sensor. Adjust the sensor to the new target and set the tilt linkage position sensor again.

ReferenceFor the correct procedure in order to set the tilt linkage position sensor, refer to the section ""Position Sensor (Tilt Linkage) - Set" ", in this manual.

Note: The target value will reset to 88.5% after three failures, or two failures if the failures are in opposite directions. Usually, if the target value resets there are other problems. Check the sensor assembly. Ensure that the roller is staying on the cam of the sensor assembly. Ensure that all of the parts are moving freely. Also, ensure that you are putting the boom and the bucket in the proper positions before pressing the "OK" key during the calibration.

The target value is a guideline that uses simple logic in providing a new value. The new target value can be ignored if the cause of the failure of the calibration is understood.

Position Sensor (Tilt Linkage) - Set

Note: This procedure only needs to be performed if the position sensor will not calibrate.

Note: A two-step process is used in order to install the position sensors for the tilt linkage and in order to adjust the position sensors for the tilt linkage. The sensor is first positioned on the shaft using the ""Position Sensor (Tilt Linkage) - Set" " procedure. The procedure that is used to set the sensor is preprogrammed in the implement ECM in order to assist the mechanic. The sensor is then calibrated using the ""Position Sensor (Tilt Linkage) - Calibrate" " procedure. This procedure programs the locations of the extreme positions of the linkage into the implement ECM. The implement ECM must know when the bucket is approaching an extreme position in order for the linkage to avoid hard impact.

1. Fully tilt the bucket into the BACK position. Lower the bucket onto the ground.

2. Connect the steering frame lock link.

3. Engage the parking brake.

4. If the machine is equipped with ride control, move the ride control switch to the OFF position.

5. Stop the engine and leave the key start switch in the OFF position.

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Illustration 138	g00286982
Left Side of the Boom (1) Tilt linkage position sensor. (2) Lever.

6. Loosen the bolt on the lever so that the shaft may be turned.

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

8. Press the "OK" key on the keypad of the center module repeatedly. The hour meter will appear on the diagnostic message screen.

   Note: The messages that appear on the diagnostic message screen may differ from the messages that are listed in this procedure.

   ReferenceRefer to the section ""Glossary of Calibration Messages" " in this manual for more information on messages that appear on the diagnostic message screen.

9. Enter "SERV (7378)" on the keypad, and press the "OK" key in order to enter the service mode. The top line should read "SELECT CALIBRATION".

   Press "OK" and try again if you can not get into the service mode. The computer will ignore the command if you wait more than 5 seconds between strokes of the keys.

10. Press the ">" key until "LINKAGE SNSRS - SET" displays on the diagnostic message screen. Press the "OK" key.

    Note: Press the "OK" key once for each error message that appears on the diagnostic message screen during this procedure. Pressing the "OK" key once for each error message will return you to the service mode. If the "OK" key is pressed too many times, you will be taken out of the service mode, or you will move forward through the instructions before you can read the instructions.

11. Press "OK" again in order to start the "LINKAGE SNSRS - SET" procedure.

12. Use the forward arrow key ">" to bring up "TILT SNSR ONLY" on the diagnostic message screen. Press "OK" in order to begin.

13. Follow the instructions on the diagnostic message screen in order to position the linkage and follow the instructions in order to complete the procedure. The target number for the tilt will be displayed on the diagnostic message screen.

14. When "PRESS OK TO SHUT DOWN ENGINE" is displayed, press the "OK" key. The engine will stop. Leave the key start switch in the ON position until adjustment of the sensor is complete.

15. The target number and the current sensor reading will be displayed on the diagnostic message screen. Use the "<" and ">" arrow keys in order to move back and forth between the target and the current values.

    Note: Caterpillar Electronic Technician (ET) may be used in order to display the output of the position sensor. This information can be displayed during the adjustment of the sensor for tilt position.

16. A Fluke meter can also be used in order to adjust the sensor.

    1. Place the prongs into the 299-BK and 762-YL wires. The 299-BK and 762-YL wires correspond to the black wire and white wire on the sensor.

    2. Select DC voltage.

    3. Press the "Hz" button twice in order to display "DUTY CYCLE %".

    4. Use the "CURRENT" value that is shown on the display if you are not using a Fluke meter.

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NOTICE
The position sensor can be damaged if too much force is applied against the internal stops of the sensor. Always use care when you turn the shaft that is attached to the sensor.

17. Use the Fluke meter or the display in the cab in order to adjust the sensor. Adjust the sensor until the reading matches the target number. ± 0.5% from the target number is acceptable. Tighten the bolt that locks the lever onto the shaft. Recheck the sensor reading after the bolt is tightened.

18. The tilt linkage position sensor must be calibrated before the machine is returned to use.

    ReferenceFor the correct procedure to calibrate the tilt linkage position sensor, refer to the section ""Position Sensor (Tilt Linkage) - Calibrate" ", in this manual.

Glossary of Calibration Messages

BOTTOM OUT LIFT CYLS THEN PRESS "OK" - Lower the boom to the lowest possible position (bottom out lift cylinders).

DUMP BUCKET FULLY THEN PRESS "OK" - Tilt the bucket forward until the bucket makes contact with the dump stop on the boom.

EXTEND LIFT CYLS FULLY THEN PRESS "OK" - Raise the boom to the maximum height (full extension of lift cylinders).

LOWER BOOM FULLY THEN PRESS "OK" - Lower the boom to the lowest possible position (bottom out lift cylinders).

LOWER BUCKET FULLY THEN PRESS "OK" - Lower the boom to the lowest possible position (bottom out lift cylinders).

RAISE BOOM FULLY THEN PRESS "OK" - Raise the boom to the maximum height (full extension of lift cylinders).

RAISE LIFT LINK FULLY THEN PRESS "OK" - Raise the boom to the maximum height (full extension of lift cylinders).

TILT BCKT BACK FULLY THEN PRESS "OK" - Tilt the bucket backward until the rack stops make contact.

TILT BCKT FWD FULLY THEN PRESS "OK" - Tilt the bucket forward until the bucket makes contact with the dump stop that is on the boom.

Steering Neutralizer Valve Adjustment

Before a new machine has been put into service, the steering stops should be checked for proper adjustment. If the machine is allowed to steer onto the mechanical stops, lower hitch damage will occur. Follow the steps below in order to verify proper adjustment.

1. Load the bucket with approximately 24 tons of material.

2. Move the machine to a location that is smooth, level, and hard. The location should also be dry and free of debris.

3. Move the transmission control lever to the NEUTRAL position and raise the bucket 0.3 m (1.0 ft) above the ground. Disengage the parking brake.

4. Run the engine at maximum RPM. Articulate the machine all the way to the right.

5. Move the steering lever fully to the left so the machine articulates at the maximum possible speed. Engage the parking brake when the machine stops moving.

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Illustration 139	g00554399
Lower articulation hitch (left side view). (1) Steering stop on loader frame. (2) Steering stop on engine end frame.

6. Measure the clearance that exists between steering stop (1) and steering stop (2). The clearance should be a minimum of 19.05 mm (0.750 inch).

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Illustration 140	g00554423
(3) Adjustment screw for the steering neutralizer valve. (4) Steering neutralizer valve.

7. If the clearance is less than 19.05 mm (0.750 inch), adjust steering neutralizer screw (3) on the upper hitch.

8. Repeat Steps 5 and 6 until there is 19.05 mm (0.750 inch) of clearance between steering stop (1) and steering stop (2). Ensure that you are fully articulating the machine from full left to full right at maximum RPM.

9. Use the same procedure in order to set the steering stops on the right side of the machine.