994D Wheel Loader Machine System Caterpillar

Installation Procedure

Note: Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary. Lubricate O-ring seals lightly with the lubricant that is being sealed.

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Illustration 1	g00617415

1. Lower the temperature of sleeve bearing (47) (not shown) to -40 °C (-40 °F). Thoroughly clean the bore of the arm. Install Tooling (A) . Install sleeve bearing (47) (not shown). Install the sleeve bearing until the sleeve bearing is 10 ± 0.5 mm (0.4 ± 0.02 inch) below the surface of the arm.

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Illustration 2	g00544366

2. Apply 7M-7456 Compound to the bore of the lever and bearing assembly prior to installation of the seals. Use a mallet in order to install two seals (46) in the lever and bearing assembly.

3. Repeat Step 1 and Step 2 for the remaining sleeve bearing and seals.

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Illustration 3	g00533695

4. Position arm and bearing assembly (14) for installation. The weight of the arm and bearing assembly with the lever and bearing assembly is 22,100 kg (48,700 lb).

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Illustration 4	g00617419

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Illustration 5	g00544371

5. If necessary, install shims (37) in order to fill the gaps between the arm and bearing assembly and the non-engine end frame.

6. Use Tooling (B) to install pin (36) . Center the pin axially. The weight of the pin is 140 kg (310 lb).

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Illustration 6	g00545266

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Illustration 7	g00544363

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NOTICE
After 50 hours of operation, tighten the collet bolts to 1800 ± 200 N·m (1330 ± 150 lb ft). Failure to tighten the collet bolts may result in damage to the machine.

7. Thoroughly clean the inside and outside of collets (34) and (35) (not shown). Apply 5P-3931 Anti-Seize Compound to the inside and outside of collets (34) and (35) (not shown) prior to assembly. Center collets (34) and (35) (not shown) in the bores of the lever and bearing assembly.

8. Apply 5P-3931 Anti-Seize Compound to the threads of bolt (33) . Install bolt (33) , the washers, and the nut into collets (34) and (35) (not shown). Perform the following steps in order to properly install the collets:

   1. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

   2. Sufficiently strike the collets with a hammer in order to cause the torque to drop to less than 950 N·m (700 lb ft).

   3. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

   4. Sufficiently strike the collet with a hammer in order to cause the torque to drop to less than 1600 N·m (1180 lb ft).

   5. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

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Illustration 8	g00533691

9. Install guard assembly (44) , as shown.

10. Install bolt (45) , the washers, and the nut.

11. Repeat Step 5 through Step 8 for the remaining pin.

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Illustration 9	g00533690

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Illustration 10	g00533688

12. Install three bolts (42) , the washers, the mounts, and the spacers in order to install sensor assembly (43) .

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Illustration 11	g00533619

13. Install three bolts (39) and the washers in order to install plate (40) .

14. Connect rod (38) to the position sensor. Connect wiring harness (41) at the electrical connection.

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Illustration 12	g00533476

15. Connect three hose assemblies (32) to manifold block (31) .

16. Repeat Step 15 for the opposite side.

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Illustration 13	g00533471

17. Install two bolts (30) and the washers in order to connect manifold (29) to the non-engine end frame.

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Illustration 14	g00533466

18. Install bolt (28) and the washer in order to connect relief valve (27) to manifold (26) .

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Illustration 15	g00533397

19. Install guard assembly (25) with four bolts (24) and the washers.

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Illustration 16	g00533163

20. Position a suitable lifting sling around lift cylinder (18) . Fasten the other end of the suitable lifting sling to a hoist. Position the lift cylinder for installation.

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Illustration 17	g00617445

21. Use Tooling (B) to install pin (23) . Center the pin axially. The weight of the pin is 66 kg (145 lb).

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Illustration 18	g00545299

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NOTICE
After 50 hours of operation, tighten the collet bolts to 1800 ± 200 N·m (1330 ± 150 lb ft). Failure to tighten the collet bolts may result in damage to the machine.

22. Thoroughly clean the inside and outside of collets (21) and (22) (not shown). Apply 5P-3931 Anti-Seize Compound to the inside and outside of collets (21) and (22) (not shown) prior to assembly. Center collets (21) and (22) (not shown) in the bores.

23. Apply 5P-3931 Anti-Seize Compound to the threads of bolt (20) . Install bolt (20) , the washers, and the nut into collets (21) and (22) (not shown). Perform the following steps in order to properly install the collets:

    1. Use Tooling (C) (not shown) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    2. Sufficiently strike the collets with a hammer in order to cause the torque to drop to less than 950 N·m (700 lb ft).

    3. Use Tooling (C) (not shown) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    4. Sufficiently strike the collet with a hammer in order to cause the torque to drop to less than 1600 N·m (1180 lb ft).

    5. Use Tooling (C) (not shown) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

24. Connect hose assembly (19) .

25. Repeat Step 20 through Step 24 for the remaining lift cylinder.

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Illustration 19	g00533159

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Illustration 20	g00533161

26. Position a suitable lifting strap around flood lighting (15) .

27. Install eight bolts (17) and the washers.

28. Connect wiring harness (16) at the electrical connection.

29. Repeat Step 26 through Step 28 for the remaining flood light.

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Illustration 21	g00533158

30. Lower arm and bearing assembly (14) from the support.

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Illustration 22	g00617454

31. Attach Tooling (D) on lever and bearing assemblies (7) .

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Illustration 23	g00541048

32. Place a suitable sling around tilt cylinder (8) . Fasten the suitable sling to a hoist. Position the tilt cylinder for installation of the pin.

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Illustration 24	g00617462

33. Use Tooling (B) to install pin (13) . Center the pin axially. The weight of the pin is 55 kg (120 lb).

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Illustration 25	g00544967

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Illustration 26	g00545225

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NOTICE
After 50 hours of operation, tighten the collet bolts to 1800 ± 200 N·m (1330 ± 150 lb ft). Failure to tighten the collet bolts may result in damage to the machine.

34. Thoroughly clean the inside and outside of collets (10) and (12) (not shown). Apply 5P-3931 Anti-Seize Compound to the inside and outside of collets (10) and (12) (not shown) prior to assembly. Center collets (10) and (12) (not shown) in the bores.

35. Apply 5P-3931 Anti-Seize Compound to the threads of bolt (9) . Install bolt (9) , the washers, and the nut into collets (10) and (12) (not shown). Perform the following steps in order to properly install the collets:

    1. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    2. Sufficiently strike the collets with a hammer in order to cause the torque to drop to less than 950 N·m (700 lb ft).

    3. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    4. Sufficiently strike the collet with a hammer in order to cause the torque to drop to less than 1600 N·m (1180 lb ft).

    5. Use Tooling (C) in order to tighten the bolt to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

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Illustration 27	g00581923

36. Connect hose assembly (11) .

37. Repeat Step 31 through Step 36 for the remaining tilt cylinder.

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Illustration 28	g00545298

38. Position link and bearing assembly (3) for installation. The weight of the link and bearing assembly is 559 kg (1230 lb).

39. Place a suitable lifting sling around pin assembly (4) . Attach the other end of the suitable lifting sling to a hoist. Install pin assembly (4) . The weight of the pin assembly is 74 kg (162 lb).

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Illustration 29	g00540978

40. Install O-ring seal (6) on pin assembly (4) .

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Illustration 30	g00532364

41. Install bolt (5) , the washer, and the spacer.

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Illustration 31	g00545268

42. Install plate (2) . Install three bolts (1) and the washers.

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Illustration 32	g00545275

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Illustration 33	g00545282

43. Remove O-ring plug (48) and the O-ring seal from link and bearing assembly (3) .

44. Add 250 cc (15.3 in³) of 2P-9863 Lubricant to the pin assembly. Use Tooling (E) in order to check the air void after adding the lubricant. Use the 30 cc (1.8 in³) calibration tube that is included with the tooling in order to calibrate Tooling (E) . The air void must be between 25 kPa (3.5 psi) and the measurement that was obtained with the 30 cc (1.8 in³) calibration tube. Add or subtract lubricant in order to achieve the correct pressure reading from Tooling (E) .

45. After the air void is correct and the correct amount of 2P-9863 Lubricant has been added, install O-ring plug (48) and the O-ring seal.

46. Repeat Step 38 through Step 45 for the remaining pin assembly.

End By: Install the bucket. Refer to Disassembly and Assembly, "Bucket - Install".