Field Assembly of 992K Wheel Loader{7000, 7960} Caterpillar

Field Assembly of 992K Wheel Loader{7000, 7960}

Usage:

992K H4C

Wheel Loader:: 992K (S/N: H4C1-UP)

Introduction

This publication contains the installation information and assembly procedures that are 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.

ReferenceParts Manual, SEBP4140 Operation and Maintenance Manual, SEBU8075 Service Manual, RENR9770

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

Do not order parts until you understand the information that is contained in this document.

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Illustration 1	g01689741

Components and Weights

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Illustration 2	g01473401

Standard machine (1) without either axle has a weight of 61240 kg (135000 lb).
Standard machine (1) with a high lift arm assembly without either axle has a weight of 62418 kg (137608 lb)
Front axle housing (2) has a weight of 6465 kg (14250 lb).
Rear axle housing (3) has a weight of 6760 kg (14900 lb).

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Illustration 3	g01473113

Cab (4) has a weight of 272 kg (600 lb).
ROPS (5) has a weight of 2480 kg (5470 lb).
Each wheel and tire (6) has a weight of 3135 kg (6910 lb).

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Illustration 4	g01492394

Bucket (7) has a weight of 9440 to 13700 kg (20800 to 30200 lb).

Note: If the rear bumper assembly needs to be installed, use 16 8T-5878 Bolts and use 16 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 5048 kg (11129 lb) with the standard lift arrangement. The weight of the rear bumper assembly is 5938 kg (13091 lb) with the high lift arrangement.

Preparation for Assembly

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Illustration 5	g01488493
Typical example

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	g01488513

Remove the panel near the top of the steps on the left side of the machine. The panel must be removed in order to install the rear axle assembly and the left rear tire. Set the panel aside for later installation.

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Illustration 7	g00115505

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.

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

Installation of the Tilt Regen Tube

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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.

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Personal injury can result from hydraulic oil pressure.
Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and the pump has been stopped.
Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.
Remove the fill plug only when the engine is stopped, and the fill plug is cool enough to touch with your bare hand.

To prevent possible injury refer to the Hydraulic System Testing And Adjusting Module, "Release Of Pressure" located in the service manual.

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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, NENG2500, "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.

Note: The linkage of the tilt cylinder should not be moved until the tilt regen tube has been securely mounted.

Remove the four 7X-2563 Bolts , four 8T-4123 Washers , two 6V-0402 Half Flanges , 5P-0050 Cover , and 1P-3709 Rectangular Seal from the top of the control valve group on the end of cylinder.

Remove two 8T-4174 Bolts , two 9X-8257 Washers , 102-8873 Plate , two 9C-6034 Spacers and 102-8872 Clamp from the top of the valve group on the end of cylinder. This hardware will be reused in order to connect the tube to the cylinder.

Remove the four 7X-2563 Bolts , four 8T-4123 Washers , two 6V-0402 Half Flanges , 5P-0050 Cover , and 1P-3709 Rectangular Seal from the rod end of cylinder.

Remove four 7X-2488 Bolts , four 8T-4123 Washers , four 8T-4131 Nuts , two 6V-0402 Half Flanges , and a 5P-0050 Cover from the end of the tube that bolts to the top of the control valve.

Remove the four 7X-2488 Bolts , four 8T-4123 Washers , four 8T-4131 Nuts , two 6V-0402 Half Flanges , and 5P-0050 Cover from the end of the tube that will bolt to the rod end of the cylinder.

Clean the mounting surfaces on the tilt regen tube. Make sure that the machined surfaces are free from dirt.

Attach an appropriate lifting device in order to support the tilt regen tube. The lifting device will support the tube while the connections to the cylinder are being made.

Connect one end of the 271-7733 Tube As to the 275-5796 Control Valve Gp .

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Illustration 8	g02133754
tilt regen tube in mounted position

Attach the tube to the control valve by using four 8T-6381 Bolts and four 8T-4123 Washers and a 1P-3709 Rectangular Seal .

Attach the 102-8872 Clamp and the 102-8873 Plate to the tilt regen tube by using two 8T-4174 Bolts , two 9X-8257 Washers and two 9C-6034 Spacers to attach the clamp and the tube to the control valve.

Attach the opposite end of the tilt regen tube to the rod end of the cylinder by using four 8T-6381 Bolts , four 8T-4123 8T-4123 Washers , and a 1P-3709 Rectangular Seal .

Installation of the Front Axle

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Illustration 9	g00115507

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

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Illustration 10	g00115509

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

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Illustration 11	g00115511

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

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

Use ten 6V-1734 Bolts (2) with 20 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 12	g00443666

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Illustration 13	g00115516

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 58960 kg (129984 lb) in order to position blocking under the machine. The machine must be high enough to install the tires on the front axle.

Installation of the Rear Axle

Note: Do not perform this procedure if the rear axle is already installed.

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

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

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Illustration 14	g00268348
Typical example

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.

Use 16 142-7074 Bolts (2) and use 16 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	g01473053

Use six 142-7074 Bolts (2) 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
Typical example

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 Front Drive Shaft, Front Brake Oil Lines, and Front Axle Oil Cooler Lines

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Illustration 17	g01488594

Connect front drive shaft (1) to the front differential. Install four 9X-6480 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 18	g01469267

Connect 312-3653 Tube As (3) to the port on the front of the axle.

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Illustration 19	g01488833
Left side of front axle (rear view) (4) 291-5621 Tube As (5) 6D-4246 Clip (6) 8F-8513 Clip (7) 5K-9660 Clip (8) 8R-8087 Spacer (9) 264-8088 Tube As (10) 7M-8798 Clip (11) 8T-4136 Bolt (12) 8T-4121 Hard Washer

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Illustration 20	g01488875
Inside loader frame above front axle (4) 291-5621 Tube As (9) 264-8088 Tube As (13) 229-5371 Hydraulic Block Gp (14) 115-2516 Block (15) 291-5620 Tube As (16) 264-8087 Tube As

Connect one end of 291-5621 Tube As (4) to the left side of 229-5371 Hydraulic Block Gp (13). 291-5621 Tube Assembly (4) is the left return line for the axle oil cooler.

Connect one end of 264-8088 Tube As (9) to 115-2516 Block (14). 264-8088 Tube As (9) is the left service brake line.

Connect the opposite end of 291-5621 Tube As (4) to the left brake housing. Connect the opposite end of 264-8088 Tube As (9) to the left brake housing.

Attach the tubes to the loader frame. Use one 8F-8513 Clip (6), one 5K-9660 Clip (7), one 8T-4136 Bolt (11), one 8T-4121 Hard Washer (12) and one 8R-8087 Spacer (8) .
Attach 6D-4246 Clip (5) and 7M-8798 Clip (10) to the tubes. Do not attach these clips to the axle at this time.

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Illustration 21	g01469812
Left side of front axle (rear view) (17) 1F-1609 Spacer (18) 5P-1076 Hard Washer (19) 8T-4648 Bolt (20) 8T-6466 Bolt (21) 7X-7729 Washer (22) 9R-2216 Boss (23) 230-7680 Guard As

Install 230-7680 Guard As (23) over the tubes. Use two 1F-1609 Spacers (17), two 5P-1076 Hard Washers (18), and two 8T-4648 Bolts (19) in order to secure the guard to the brake housing.
Use 8T-6466 Bolt (20), 7X-7729 Washer (21) and 9R-2216 Boss (22) in order to secure the guard to the axle housing. Place boss (22) between the guard and the clips that were attached to the tubes in Step 6.

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Illustration 22	g01469268
Right side of front axle (rear view) (6) 8F-8513 Clip (10) 7M-8798 Clip (12) 8T-4121 Hard Washer (15) 291-5620 Tube As (16) 264-8087 Tube As (24) 6D-4244 Clip (25) 8T-4196 Bolt (26) 2S-4762 Clip

Install 264-8087 Tube As (16) and 291-5620 Tube As (15) on the right side of the front axle. 264-8087 Tube As is the right service brake line. 291-5620 Tube As is the right return line for the axle oil cooler.

Install 230-7679 Guard As over the tubes on the right side of the axle.

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Illustration 23	g01469856
Front axle (rear view)

Connect front wiring harness (27) to the wiring harness for the temperature sensor on the axle. Use two 4D-8123 Clips (28) in order to secure the harness to the axle housing.

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Illustration 24	g01469908

Connect 317-5602 Hose As (29) to the port at the bottom of the differential.

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Illustration 25	g01469910

Install 237-4686 Plate (30) on the axle housing. Use two 7X-0389 Bolts and two 242-0315 Spacers in order to install the plate.

Installation of Rear Drive Shaft, Rear Brake Oil Lines, and Rear Axle Oil Cooler Lines

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Illustration 26	g00268356

Connect the rear drive shaft (1) to the rear differential. Install four 9X-6480 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 27	g01471418
Front trunnion (top view) (3) 313-4443 Axle Harness (4) 5P-9085 Clip

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Illustration 28	g01471419
Rear axle (front view) (3) 313-4443 Axle Harness (4) 5P-9085 Clip (5) 4D-8123 Clip (6) 288-8390 Temperature Sensor Gp

Connect 313-4443 Axle Harness (3) to temperature sensor (6). Refer to Illustration 27 and Illustration 28 for the routing of the harness.

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Illustration 29	g01471454
Rear axle (front view) (7) 315-4138 Hose As (8) 229-5373 Hydraulic Block Gp (9) 314-7943 Hose As (10) 115-2516 Block (11) 282-3255 Tube As (12) 317-5414 Hose As

Connect 314-7943 Hose As (9) to 115-2516 Block (10) .

Connect 315-4138 Hose As (7) to 229-5373 Hydraulic Block Gp (8) .

Connect 282-3255 Tube As (11) to the top of the front trunnion support.

Connect 317-5414 Hose As (12) to the axle housing.

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Illustration 30	g01471456
Rear axle (rear view) (13) 282-3252 Tube As (14) 275-7769 Hose As

Connect 282-3252 Tube As (13) to the top of the rear trunnion.

Connect 275-7769 Hose As (14) to the top of the rear axle.

Installation of the Tires

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Illustration 31	g01489274

Install two 138-8698 Rods into one of the wheels of the front axle. The rods will be used in order to help guide the tire and rim onto the wheel.

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Illustration 32	g00115530

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 2J-3507 Full Nut with a 5P-8250 Washer onto each of the rods in order to hold the tire and rim assembly in place.

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Illustration 33	g00115531

Install 46 9X-8898 Bolts (1) with 5P-8250 Washers (2) in the rim assembly. Tighten all of the bolts and the nuts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

Repeat Step 1 through Step 3 in order to install the remaining tires on the machine.

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

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Illustration 34	g01488513

Reinstall the panel on the left side of the machine.

Installation of the Cab

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Illustration 35	g01463698

Ensure that 4E-6510 Seal (A) is located on the bottom portion of the cab. Ensure that 4E-6509 Seal (B) is located on the bottom portion of the cab. Ensure that two 256-2454 Seals (C) are located on the bottom portion of the cab.

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Illustration 36	g00888746

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Illustration 37	g00889805

Remove two nuts (1) and the washers from each side of the cab.

Install 9U-2670 Handhold (2) to the right side of the cab with two nuts (1) and the washers.

Install 9U-1301 Handhold (3) to the left side of the cab with two nuts (1) and the washers.

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Illustration 38	g00892110

Route wires (4) and (5) for the antenna toward the front of the cab for later connection to the ROPS.

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Illustration 39	g01473112

Install 219-8090 Suspension Seat Gp (6) and seat supports (7, 10) in the cab with four 168-4510 Bolts (8) and with four 8T-4121 Washers (9) .

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Illustration 40	g01489313

Attach the armrests to the seat supports. Use two 211-4942 Knob As in order to secure each armrest.

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Illustration 41	g00117913

Note: Remove the front 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 42	g00444024

Attach an appropriate lifting device to the four brackets that are located on the top of the cab.

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Illustration 43	g01473136

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 (D) 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 44	g01473193
Front of the cab

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Illustration 45	g01473194
Rear of the cab

Secure the top portion of the cab with 20 8T-4196 Bolts (12) and with 20 8T-4121 Hard Washers (11) that are located around the platform.

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Illustration 46	g01473213

Connect the wiring harness (14) 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 (13) .

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Illustration 47	g01473216

Reinstall the front instrument panel with four 9X-2046 Screws (15) .

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Illustration 48	g01473233

Connect electrical connector (16) that is located near the right rear corner of the cab.

Connect hose assembly (17) that is located near the right rear corner of the cab to the rear wiper.

Install the right side control panel.

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Illustration 49	g01473237

Install 123-8725 Insulation (18) over the right rear inside post of the cab.

Install two 7T-4306 Louver As (19) into insulation (18) .
Note: In order to install louver assemblies (19), the fabric that covers the openings in the louver will need to be cut.

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Illustration 50	g01473239

Install 4E-7205 Seal (21) around the bottom of 123-8722 Duct (20) prior to installing the duct.

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Illustration 51	g01473241

Install duct (20) behind the seat. Secure duct (20) with six 8T-4189 Bolts (22) and 8T-4896 Washers .

Install 103-2543 Seal (23) on duct (20) on the contact surface for the air filter.

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Illustration 52	g01473372

Install 9X-8216 Air Filter (24) in the opening of duct (20) .

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Illustration 53	g01473373

Install 4E-7204 Cover As (27) with two 7K-3262 Screws (25) and 2R-2376 Washers .

Install two 8T-5027 Nuts (26) and 9X-2045 Screws in order to plug the unused holes.

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Illustration 54	g01473374

Install 123-8724 Insulation (28) over the left rear inside post of the cab.

Install 6V-8928 Coat Hook (31) with one 9X-2042 Screw (29) .

Install 3E-6389 Dome Lamp (30) onto insulation (28) with three 9X-1046 Screws .

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Illustration 55	g01492493

Install 251-4646 Headliner (33) at the top of the door frame. Use three 8T-5027 Nuts (26) and three 111-4627 Screws (32) in order to install the headliner.

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Illustration 56	g01492853

Install 251-4645 Rear Panel (34) at the rear of the door frame. Use three 8T-5027 Nuts (26) and three 111-4627 Screws (32) in order to install the rear panel.

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Illustration 57	g01493073

Install 251-6492 Strip (35) at the bottom of the door frame. Use six 9X-2042 Screws (36) in order to install the strip.

Install the floor mat in the cab.

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Illustration 58	g01473375

Install 123-8721 Duct (38) over the vent of the existing air duct (E) .

Install 090-4808 Seal (37) around the top opening of the 123-8721 Duct (38) .

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Illustration 59	g01473376

Install 213-4262 Seal (39) on the mating surface of the lower duct that is located on the right-hand side of the cab.

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Illustration 60	g00900567

Verify that the seals are in place on 138-8630 Duct .

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Illustration 61	g01473377

Install 138-8630 Duct (41) .

Install four 8T-4196 Bolts (40) and 8T-4121 Hard Washers .

Install two 8T-5027 Nuts (26) and 9X-2045 Screws on duct (41) in order to plug the unused holes.

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Illustration 62	g01473378

Install 4E-9640 Handle (45) .

Install two 8T-4183 Bolts (44) and 8T-4223 Hard Washers in order to secure the handle.

Install three 8Y-6352 Louver As (42) .

Install ten 8Y-6388 Louver As (43) with 20 104-2091 Flat Head Screws .

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Illustration 63	g01473379
Cover over right side control panel

Install 205-3076 Cover As (47) with three 9X-2042 Screws (46) .

Install 5L-6766 Plug (48) in the hole in the cover.

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Illustration 64	g01473382

Remove three bolts (49), the washers, and channel (50) .

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Illustration 65	g01473384

Connect tube assemblies (51) and (52) .

Connect electrical connector (53) .

Install 8T-4191 Bolt (54), 8T-4121 Hard Washer , 4K-8864 Clip , 5P-9297 Clip , and 7N-3718 Clip .

Install channel (50), three bolts (49), and the washers.

Refer to Step 50 and Step 51 if the machine is equipped with the 267-8836 Camera . If the machine is not equipped with the 267-8836 Camera , continue to ""Installation of Steps and Handholds" ".

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Illustration 66	g01473385

Mount 251-4157 Display Module Gp (55) on upper right door post.

Connect the electrical connector for the camera to the rear of the front display.

Note: Refer to Parts Manual, SEBP4140, "992K Wheel Loader" for details of the 252-9529 Camera Mounting Gp and 282-4890 Camera Wiring Gp .

Installation of Steps and Handrails

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Illustration 67	g01496753
Rear left-hand side of machine

Install 355-9649 Step Group (5) on the left rear side of the machine. Use four 8T-4194 Bolts (3) with four 5P-1076 Hard Washers (4) to attach the step group.

Install 300-6344 Handle (1) on the left rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4).

Install 300-6343 Handle (2) on the left rear bumper. Secure the handle with four 8T-4194 Bolts (3) and four 5P-1076 Hard Washers (4) .

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Illustration 68	g01473387
Rear right-hand side of machine

Install 355-9649 Step Group (5) on the right rear side of the machine. Use four 8T-4194 Bolts (3) with four 5P-1076 Hard Washers (4) to attach the step group.

Install 300-6344 Handle (1) on the right rear bumper. Secure the handle with four 8T-4194 Bolts (3) and four 5P-1076 Hard Washers (4) .

Install 300-6343 Handle (2) on the right rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4) .

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Illustration 69	g01854594
Left-hand platform access

Install 325-7352 Handrail Assembly (10) on the step assembly. Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Install 325-7350 Handrail Assembly (7). Secure the handrail assembly with four 8T-4139 Bolts (11) and four 8T-4223 Hard Washers (12) .

Connect 325-7352 Handrail Assembly (10) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

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Illustration 70	g01856256
Left-hand platform

Install 325-7347 Handrail Assembly (13). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Connect 325-7347 Handrail Assembly (13) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

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Illustration 71	g01856258
Left-hand front platform

Install 325-7349 Handrail Assembly (14). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Connect 325-7349 Handrail Assembly (14) to the 325-7347 Handrail Assembly (13). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

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Illustration 72	g01473391

Install 301-5792 Handrail Assembly (15). Secure the handrail assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

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Illustration 73	g01850941

Install 301-5791 Handrail Assembly (49). Secure the handrail assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

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Illustration 74	g01860133
Right-hand side of machine

Install 325-7351 Handrail Assembly (20) on the step assembly. Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Install 325-7350 Handrail Assembly (7). Secure the handrail assembly with four 8T-4139 Bolts (11), and four 8T-4223 Hard Washers (12) .

Connect 325-7351 Handrail Assembly (20) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8) , two 7X-7729 Washer (9), and one 8T-4133 Nut (46) .

Install 325-7346 Handrail Assembly (17). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Connect 325-7346 Handrail Assembly (17) to the 325-7350 Handrail Assembly (7) with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

Install 325-7348 Handrail Assembly (18). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

Install 325-7353 Gate Assembly (16). Secure the handrail assembly with two 323-3747 Brackets (45) with four 8T-4195 Bolts (8) and four 8T-4121 Hard Washer (44) to 325-7346 Handrail Assembly (17).

Secure 323-3746 Brackets (50) with four 8T-4195 Bolts (8) and four 8T-4121 Hard Washer (44) to 325-7353 Gate Assembly (16).

Secure 323-3749 Bracket (39) with two 8T-4195 Bolts (8) and two 8T-4121 Hard Washers (44) to 325-7353 Gate Assembly (16) .

Secure gate assembly with two 8T-6466 Bolts (40), two 127-0366 Spacers (41), two 161-3357 Spacers (42), four 7X-7729 Washers (9), and two 096-4883 Locknuts (43) .

Confirm easy outward opening of the gate.

Secure the 300-4511 Latch Assembly (35) to the 325-7348 Handrail Assembly (18) with two 248-0102 U-Bolts (36), four 8T-4224 Hard Washers (37), and four 5C-7261 Nuts (38). The latch assembly must be assembled so the latch rod can go through the hole of the 323-3749 Bracket (39). Bracket (39 ) is attached to the gate assembly.

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Illustration 75	g03490799
(35) 300-4511 Latch As (K) 25 mm (0.98 inch)

Orient Latch As (A) for proper assembly and clearance. Refer to Illustration 75.

Install 325-7354 Ladder Assembly (19) on the right side of the machine. Secure the ladder assembly with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4) .

Assemble two 323-3748 Belts (34) with two 4V-9803 Plates (31), four 8T-4184 Bolts (33), and four 6V-7687 Locknuts (32). Refer to Illustration 74.

Assemble four 325-7233 Bracket Assemblies (47) to the 323-3748 Belts (34). Install the bracket assemblies with four 4V-9802 Bar (27), eight 8T-4138 Bolts (29), and four 6V-7687 Locknuts (32). Refer to Illustration 74.

Assemble two 323-3751 Step Assemblies (20) on the 325-7233 Bracket Assemblies (47). Secure the step assemblies with four 5P-2228 Bolts (28), four 8T-4223 Hard Washers (12), and four 8F-6437 Washers (30). Refer to Illustration 74.

Install rubber mounted steps to the bottom of the ladder assembly.

Install 301-5791 Handrail Assembly (14). Secure the handrail assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

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Illustration 76	g01845153
Left-hand side of platform

Install the 325-7381 Toe Guard (21). Secure toe guard with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4). Refer to Illustration 76.

Install 325-7378 Toe Guard (22) with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4) .

Install 325-7380 Toe Guard (23). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4) .

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Illustration 77	g01845180
Right-hand side of platform

Install 325-7381 Toe Guard (21). Secure toe guard with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4). Refer to Illustration 77.

Install 325-7377 Toe Guard (26). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4). Refer to Illustration 77.

Install 325-7382 Toe Guard (25). Secure toe guard with three 8T-4192 Bolts (48) and three 5P-1076 Hard Washers (4). Refer to Illustration 77.

Install 325-7379 Toe Guard (24). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4). Refer to Illustration 77.

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Illustration 78	g02454396
View of rear guardrails

Install 350-7160 Guardrail As (50) to the right rear side of the machine. Secure guardrail (50) to the side of the machine with four 8T-4139 Bolts and four 7X-3392 Hard Washers . Secure guardrail (50) to the rear of the machine with two 8T-4139 Bolts and two 5P-1076 Hard Washers . Refer to Illustration 78.

Install 350-7161 Guardrail As (51) to the left rear side of the machine. Secure guardrail assembly using Step 42. Refer to Illustration 78.

Installation of Product Link (if equipped)

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Illustration 79	g01500914
(1) 263-9088 Communication Electronic Control Module (2) 290-2227 Plate As (3) 6V-8490 Bolt (4) 9X-8256 Washer

Attach 263-9088 Communication Electronic Control Module (1) to 290-2227 Plate As (2). Use four 6V-8490 Bolts (3) and four 9X-8256 Washers (4) in order to connect the module to the plate. Tighten the bolts to a torque of 3.5 ± 1.0 N·m (30 ± 9 lb in).

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Illustration 80	g01500915

Mount the plate with the communication ECM to the underside of the ROPS. Use two 8T-4121 Hard Washers and two 8T-4136 Bolts in order to mount the plate to the canopy. Connect the ROPS wiring to the communication ECM.

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Illustration 81	g01500916
Left side of ROPS canopy (5) 270-8544 Bracket As (6) 8T-4137 Bolt (7) 8T-4121 Hard Washer

Attach 270-8544 Bracket As (5) to the left side of the ROPS canopy. Use two 8T-4137 Bolts and two 8T-4121 Hard Washers in order to attach the bracket.

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Illustration 82	g01500917
Left side of ROPS canopy (8) 310-2391 Antenna As (9) 9X-6772 Cable Strap (10) 4P-7581 Clip

Attach 310-2391 Antenna As (8) to the 270-8544 Bracket As . Tighten the nut on the antenna to 5.0 ± 0.5 N·m (44 ± 4 lb in). Attach 4P-7581 Clip (10) to the bracket. Use one 9X-6772 Cable Strap (9) in order to strap the antenna cable to the clip. Use an additional cable strap in order to strap the cable to the link on the underside of the bracket.

Attach the antenna cable to the communication ECM. Use cable straps in order to strap the cable to the underside of the ROPS canopy.

Installation of the ROPS

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Illustration 83	g00443945

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Illustration 84	g00444065

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. In order to install the ROPS, the pictured cover assemblies are to be removed.

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Illustration 85	g00443235
Typical example

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 86	g00444133

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 87	g00443649
Typical example

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 88	g01493613

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

Secure the ROPS with 20 8C-3236 Bolts (3) and 20 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).

Reinstall 113-6026 Cover Assembly (1) and 113-6027 Cover Assembly (2) that were removed in Step 1.

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Illustration 89	g01473380

Connect the wiring harness on the right ROPS post to the wiring harness on the machine.

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

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Illustration 90	g02342759

Place 292-2323 Film (1) onto 302-5176 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.

Install 302-5176 Cover (2) onto the top rear of the ROPS.

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Illustration 91	g02342770

Install 9X-9365 Bracket (3) onto the left and right side of the top rear of the ROPS. Use two 8T-4121 Hard Washers (4) and two 8T-4137 Bolts (5) in order to secure the bracket.

Connect the wire harnesses to 353-2833 Flood Lamp Gp (12). Mount one flood lamp to each bracket assembly with one 8T-4195 Bolt (6), one 8T-4122 Hard Washer (7), 8T-4133 Nut (8), two 7X-7729 Hard Washers (9), 099-5307 Grommet (10) and 353-2835 Mounting Bracket As (11) .

Torque the bolt to 35 N·m (26 lb ft).

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Illustration 92	g02342458

Connect the wire harness to each 353-2833 Flood Lamp Gp (12). 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 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), 7X-7729 Hard Washer (9) and 8T-4195 Bolt (6) .

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Illustration 93	g02342846

Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the right rear side of the radiator guard with 4E-8976 Bracket (14). Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6) .

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Illustration 94	g02342855

Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the left rear side of the radiator guard with 4E-8975 Bracket . Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6) .

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Illustration 95	g02342940

Place 292-2322 Film (16) onto 9U-3663 Plate Assembly (17) .
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.

Mount 9U-3663 Plate Assembly (17) onto the front of the ROPS with five 6V-3822 Bolts (19) and five 6V-5839 Washers (20) .

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Illustration 96	g02342943

Install 164-1990 Bracket Assembly (21) onto the right side of the ROPS and install 315-3461 Bracket Assembly onto the left side of the ROPS. Secure each bracket assembly with four 8T-4184 Bolts (22) and four 198-4778 Hard Washers (23) .

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Illustration 97	g02342958

Attach two 126-7222 Angles (28) to each bracket assembly. Use one 8T-4136 Bolt with one 7X-7729 Washer in order to assemble each angle to the bracket.

Mount one 5P-6879 Mirror (27) to the angles on each bracket assembly. Secure each mirror with two 8T-4136 Bolts (26), with two 7X-7729 Washers (25) and with two 6V-7744 Locknuts (24) .

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Illustration 98	g02342960
Installation of right side mirror (29) 5P-6879 Mirror (30) 6K-5290 Clip (31) 6K-5291 Clip (32) 5P-7468 Clip (33) 5P-7469 Clip (34) 6V-1874 Grommet (35) 7X-0563 Hard Washer (36) 7X-7729 Washer (37) 8T-0389 Locknut (38) 8T-4185 Bolt (39) 8F-0492 Spacer (40) 8T-4195 Bolt (41) 7U-1903 Support

Install mirrors on the handrails on each side of the cab. Refer to Illustration 98.

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Illustration 99	g02342982

Install 324-0147 Step Assembly (42) on the lower right front of the cab. Install 324-0146 Step Assembly on the lower left front of the cab. Secure each step assembly with two 8T-4195 Bolts (43) and two 8T-4121 Washers (44) .

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Illustration 100	g02342996

Position the exhaust stacks (45) over the holes in the hood. Secure the exhaust stacks to the top of the hood. Use four 8T-4183 Bolts (46) and four 5P-1076 Hard Washers on each exhaust stack.

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Illustration 101	g01690893
Front view of ROPS

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Illustration 102	g02343000
View of area (A) and area (B) .

Attach 9U-2330 Antenna Mount (48) to the ROPS. Attach 9U-2331 Antenna Assembly (47) to 9U-2330 Antenna Mount (48) .

Attach 9U-2330 Antenna Mount (50) to the ROPS. Attach 9U-2332 Citizens Band Antenna Assembly (49) to 9U-2330 Antenna Mount (50) .

HID Lights (If Equipped)

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Illustration 103	g02342877

Connect the wire harness to each 347-9427 Flood Lamp Gp (1) and 332-9402 Flood Lamp Gp (2). Mount flood lamps (1) and (2) to the top left and right corners of the ROPS. Mount both the left and right side floodlights with 373-1524 Bracket (3), two 7X-7729 Washers (4) and two 8T-4195 Bolts (5). Repeat this step on the opposite side of the machine.

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Illustration 104	g02342897

Connect the wire harness to each 347-9427 Flood Lamp Gp (1). Mount flood lamp (1) to the top left and right corners of the radiator guard. Mount the right side floodlight with 283-9815 Bracket (7), four 8T-4121 Washers (6) and four 8T-4195 Bolts (5) .

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Illustration 105	g02342917

Connect the wire harness to each 347-9427 Flood Lamp Gp (1). Mount flood lamp (1) to the top left and left corners of the radiator guard. Mount the left side floodlight with 285-5531 Bracket (8), four 8T-4121 Washers (6) and four 8T-4195 Bolts (5) .

Heated Mirrors (if equipped)

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Illustration 106	g02377257
202-8649 Mirror As (Heated mirror) (1) 9X-6772 Cable Strap (2) 130-5301 Clip (3) 4D-8123 Clip (4) Two mounting bolts

Attach 4D-8123 Clip (3) to the top bracket for each mirror. Attach 130-5301 Clip (2) to the lower front bolt that mounts the bracket to the ROPS. Route the wiring harness for the mirror. Refer to Illustration 106. Use two 9X-6772 Cable Straps (1) in order to secure each harness to the bracket. Connect the harness to the wiring harness on the ROPS.

Secure mounting bolts (4) to 3.5 ± 0.5 N·m (2.58146 ± 0.375 lb ft).

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Illustration 107	g02423277
(5) Heated mirror switch

Turn on the heated mirrors. Confirm that the mirrors are heated within 5 minutes.

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.

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Table 1
Required Tooling for Installation of the Bucket
Quantity	Part Number	Description
1	318-2117	Plate
1	322-0101	Plate
1	318-2120	Plate
1	289-0013	Puller Stud
4	8H-3390	Full Nut
4	3S-6162	Hard Washer
1	6V-0014	Hydraulic Cylinder Gp
1	6V-2073	Bushing

Position the bucket on the ground in front of the machine.

Thoroughly clean the pin bores of the bucket and the lift arms. Apply 5P-3931 Anti-Seize Compound to the pin bore of the bucket and the lift arms.

Align the pin bores in the lift arm with the pin bores on the bucket.

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Illustration 108	g01471972
311-1898 Cartridge As (1) Oil port (A) 120 degree angle

Insert a 311-1898 Cartridge As into the B-pin joint on the right side of the machine. Install the cartridge so that the smaller diameter is toward the centerline of the machine. The dowel holes in the cartridge should face away from the machine. Push the cartridge through the lift arm until the inboard end of the cartridge is resting in the inside bore of the bucket hinge plate. Orient the cartridge so that the oil port on the cartridge is positioned within 60 degrees of the top of the cartridge. Refer to Illustration 108.

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Illustration 109	g01472090
Tooling for installation of B-pin (2) 289-0013 Puller Stud (3) Two 3S-6162 Hard Washers (4) 322-0101 Plate (5) 318-2117 Plate (6) Two 8H-3390 Full Nuts (7) 318-2120 Plate (8) 6V-0014 Hydraulic Cylinder Gp with 6V-2073 Bushing

Slide 289-0013 Puller Stud (2) through the hole in the cartridge.

Place 318-2117 Plate (5) over puller stud (2) on the inside of the bucket hinge plate. Install two 3S-6162 Hard Washers (3) and two 8H-3390 Full Nuts (6) in order to secure plate (5) .

Place 322-0101 Plate (4) over puller stud (2) on the outside of the bucket hinge plate.

Place 6V-0014 Hydraulic Cylinder Gp with 6V-2073 Bushing (8) over the puller stud on the outside of the bucket hinge plate.

Place 318-2120 Plate (7) over puller stud (2) on the outside of the bucket hinge plate. Install two 3S-6162 Hard Washers (3) and two 8H-3390 Full Nuts (6) in order to secure plate (7) .

Begin to press the cartridge into the bore.

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Illustration 110	g01472136
B-pin (sectional view) (9) 9S-8009 O-Ring Plug (10) 281-7190 Retainer (11) 316-6506 Spacer

The bore for the retainer is in the top of the lift arm. When the groove in the cartridge is visible in the retainer bore, place 281-7190 Retainer (10) in the retainer bore. The retainer will drop into the groove in the cartridge when the cartridge is correctly centered in the lift arm.

Install 316-6506 Spacer (11) on top of retainer (10) .

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Illustration 111	g01472414
(9) 9S-8009 O-Ring Plug (12) 4K-1388 O-Ring Seal

Insert 241-4960 Shims on top of spacer (11) in order to minimize the gap between the spacer and the plug. Assemble 4K-1388 O-Ring Seal (12) to 9S-8009 O-Ring Plug (9). Install 9S-8009 O-Ring Plug (9) on top of the shims.

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Illustration 112	g01472416
Alignment of dowel holes

Align the dowel holes in the outboard end of the cartridge with the dowel holes in the insert in the bucket. Install two M16x2 bolts into the outside collar of the cartridge. The bolts should be separated by 180 degrees. Use a pry bar in order to turn the collar clockwise. Continue turning until the dowel holes in the collar are aligned with the dowel holes in the insert.

Install two 266-6039 Dowel Pins into the holes. The dowels should be separated by 180 degrees. Tap in the dowels with a hammer. The taper of the dowel will align the collar with the insert. After installing the first two dowels, install the two remaining dowels.

Repeat Step 4 through Step 15 for the B-pin joint on the opposite side of the machine.

Do not install the end plates for the B-pin joint until both pins have been fully installed in the C-pin joints.

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

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Illustration 113	g01472452

Use a suitable lifting device in order to raise bucket link (13) into position. The weight of bucket link (13) is approximately 544 kg (1200 lb) for the standard lift machine. The weight of bucket link (13) is approximately 580 kg (1280 lb) for the high lift machine. Align the bores in bucket link (13) with the bores in the bucket.

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Illustration 114	g01472453

Install 4E-5597 Pin As (14) into the bore.

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Illustration 115	g01466588

Position 4E-5609 Plate (16). Use two 7X-2552 Bolts (15) and two 9X-8257 Washers in order to install plate (16) over the pin retainer.

Repeat Step 19 through Step 21 for the C-pin joint on the opposite side of the machine.

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Illustration 116	g02454564
(17) 372-2479 Block (18) 8T-4648 Bolt (19) 8T-4223 Hard Washer

Remove block (17), bolts (18), and washers (19) from both sides of the machine before operation.
Note: Retain the block and hardware for future transportation of the machine.
Note: Step 23 is ONLY for High Lift machines.

After both pins have been fully installed in the C-pin joints, cycle the lift arms several times. The cycles need to be from the fully lowered position to the fully raised position. Also, tilt the bucket several times through the full range of motion. This procedure will center the lift arms in the bucket hinge plate. The sides of the machine must be level in order to properly center the lift arms. Check the lift arms in order to confirm that the lift arms are centered in the bucket hinge plate.

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Illustration 117	g01493700

Install a 251-9677 Retainer Plate on each end of the B-pin joint. Use 251-9678 Plates and 251-9680 Plates behind the retainer plate in order to achieve a gap of 0.75 ± 0.25 mm (0.030 ± 0.010 inch) between the face of the insert and the back face of the retainer plate. Use eight 118-7313 Bolts and eight 5P-8247 Hard Washers in order to attach each plate.

Test Product Link

Product Link may need up to 15 minutes in order to establish communication with a satellite. Allow a minimum of 15 minutes to complete the following procedure.

In order to establish communication, the antenna for the Product Link module must have a clear view of the sky. Objects that obstruct the view of the antenna to the sky may result in a failure. If the antenna was obstructed during the test, retest the Product Link system with an unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees above the horizon. Check the following web site for satellite coverage in your area:

http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html

Connect Caterpillar Electronic Technician (ET) to the machine. The ET connector is located on the control panel on the right side of the cab.

Turn the engine start switch to the ON position.

Open the ET software program.

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Illustration 118	g01500919

ET will display a list of available electronic control modules. Select "Product Link". Press the "OK" button.

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Illustration 119	g01500920

Select "Diagnostic Tests" from the "Diagnostics" menu. Select "Wiggle Test".

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Illustration 120	g01459623

Read the warning that appears on the screen. Select the "OK" button.

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Illustration 121	g01459630

Select the "Groups" button near the bottom right corner of the screen.

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Illustration 122	g01459634

Choose the "New" button in order to create a new group for Product Link.

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Illustration 123	g01459640

Type "Product Link". Select the "OK" button.

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Illustration 124	g01459645
Available parameters and location of right arrow

In the left-hand column of available parameters, select "Number of GPS Satellites" under "Product Link". Then select the right arrow. In the left-hand column, select "Satellite Communications Status" under "Product Link". Select the right arrow.

Select the "OK" button.

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Illustration 125	g01459648

Select "Product Link". Press the "OK" button.

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Illustration 126	g01459655

In order to confirm the two types of communication with the satellite, the "Number of GPS Satellites" should be at least one. The "Satellite Communication Status" should be "Established". The screen in Illustration 126 shows that communication with GPS and the satellite is established.
If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Established", the communication of Product Link is confirmed.
If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Not Established", the wiggle test can be run in order to monitor status of the communication. Select the "Start" button in order to begin the wiggle test.
Note: Leave ET running and do not navigate to a different screen in ET while the wiggle test is running. These actions will end the wiggle test. Allow the wiggle test to run for at least 15 minutes before failing Product Link.
If a parameter changes during the wiggle test, the parameter will be highlighted in red. A 2 second beep will sound an alert. The parameter will remain red even if the parameter changes back to the original value.
If communication is not established and the test has run for more than 15 minutes, check the antenna for damage. Also check the connection between the antenna and the radio. If the cable does not have a good connection, reconnect the cable. Repeat the test.
If the connection between the antenna and the radio is good and no communication is established, refer to Troubleshooting, RENR7911, "Product Link 121/321".

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.

Load the bucket with approximately 24 tons of material.

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

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.

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

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

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Illustration 127	g00554399
Lower articulation hitch (left side view) (1) Steering stop on loader frame. (2) Steering stop on engine end frame.

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

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

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.