994H Wheel Loader Assembly Procedure{7000, 7960} Caterpillar

Wheel Loader:

994H (S/N: DWC1-UP)

Introduction

This Special Instruction contains the assembly procedure and the installation information that is required to assemble the 994H Wheel Loader when the machine is shipped to the field.

Show/hide table

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

Show/hide table

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.

Show/hide table

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 surfaces before you install any parts.

ReferenceParts Manual, SEBP3851:Operation and Maintenance Manual, SEBU7885: Service Manual, RENR6300

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

Illustration 1	g02631377
REPLACE WITH COMPLETED MACHINE FROM TANAJA HILLS

Site Preparation

Choose a flat, drained area for assembly. The area should have the following dimensions: 24 m (78 ft) long by 24 m (78 ft) wide. Place the rear axle in the center of the area. Leave the axle on the shipping supports until the axle is installed on the chassis.

Remove the shipping supports from the chassis and place the chassis in position over the rear axle. As the rest of the components are unloaded, place the components near the chassis.

Leave space in order to allow movement of the cranes. Place the large wooden boxes out of the way.

Note: Do not open the bags of hardware. The bags of hardware are marked for easy identification and for orderly use.

Parts Identification and Organization

Organize the parts that are shipped with the machine. Organizing the parts will reduce the number of lost parts and will reduce the amount of time that is lost in searching for parts.

Table 1

Publications in Crate 1
Operation and Maintenance Manual	SEBU8650
Assembly Guide	REHS4997
Parts Book	SEBP5739
Emissions Control	SMBU6981

Table 2

Crate 1
Front Axle Kit
367-7943	Brake Cooling Lines Gp	1
367-9452	Service Brake Lines Gp	1
319-0796	Sensor Wiring Gp	1
252-6962	Brake Lines Guard Gp	1
388-3399	U. S. Film Gp (Optional)	1

Table 3

Crate 2
Rear Axle Kit
367-7944	Brake Cooling Lines Gp	1
367-7950	Service Brake Lines Gp	1
365-5976	Sensor Wiring Gp	1
246-6150	Drive Shaft	1

Table 4

Crate 3
Pins Kit
245-1565	Linkage Pin and Seal Gp	1
9X-7703	Seal Pin	4

Table 5

Crate 4
Engine Install Kit
184-3214	Air Cleaner Gp	1
267-4456	Fumes Disposal Gp	1
267-4458	Dust Ejector Gp	1
133-6503	Filter Change Indicator Gp	1
133-6613	Precleaner Gp	1
311-3616	Air Cleaner Mounting	1

Table 6

Crate 5
Exhaust Expansion Kit
135-3879	Exhaust Extension Gp	1

Table 7

Shipping Floor
315-3576	Rear View Mirror Gp - STD	1
315-3577	Rear View Mirror Gp - Heated	1
143-3604	Rear View Mirror Gp	1
337-3371	Warning Beacon Lighting Ar	1
360-1634	Communication Wiring Gp	1
314-6934	Antenna Mounting Gp	1 (2)
363-7177	Sensor Wiring Gp	1
351-3667	Platform Guard Gp (Toe)	1
351-3692	Walkway Gp	1

Table 8

Crate 6
ROPS/Wiring/Sensor Kit
368-9169	Access Cover Gp	1
367-9500	Cover Fastener Gp	1
326-2325	Position Sensor Gp	1
350-8892	Cab Lift Mounting Gp	1
365-5972	Wiring Harness Fastener Gp	1
368-4192	Film Gp	1
165-4012	ROPS Fastener Gp	1
389-8551	Cab Mounting Gp	1
377-8828	Lines Fastener Gp	1
326-6473	Sensor Wiring Gp	1 (1)
326-6474	Sensor Wiring Gp
332-1450	Sensor Wiring Gp
332-1451	Sensor Wiring Gp

( 1 )

Only one per machine. The groups are specific to the linkage purchased.

Table 9

Crate 7
Guards/Walkway Kit
370-6604	Walkway Gp	1
336-0465	Bottom Guard Gp	1
351-3671	Handrail Fastener Gp (Toe Guards)	1
336-0807	Bottom Guard Fastener Gp (Belly Guards)	1
351-3666	Platform Mounting Gp (Front Walkway)	1
367-9499	Walkway Fastener Gp (Rear Walkway)	1
362-7754	Step and Handrail Ar	1

Table 10

Crate 8A (Optional)
416-9850 Flood Lighting Ar
348-4856	Light Switch	1
351-7158	Stop Lighting Gp	1
416-9841	Flood Lighting Gp	1
416-9842	Flood Lighting Gp	1
416-9843	ROPS Lighting Gp	1
416-9844	Flood Lighting Gp	1
416-9845	Flood Lighting Gp	1
416-9846	ROPS Lighting Gp	1
337-5203	Machine Wiring Gp	1
360-1635	Communication Wiring Gp	1

Table 11

Crate 8B (Optional)
416-9840 Flood Lighting Ar
319-0799	ROPS Lighting Gp	1
319-0805	Flood Lighting Gp	1
319-0807	Flood Lighting Gp	1
348-4856	Light Switch	1
351-7145	Flood Lighting Gp	1
351-7149	Flood Lighting Gp	1
351-7155	ROPS Lighting Gp	1
351-7158	Stop Lighting Gp	1
337-5203	Machine Wiring Gp	1
360-1635	Communication Wiring Gp	1

Table 12

Crate 9
Large Shippable Hardware Kit
366-1707	Fastener Gp	1
351-3672	Handrail Fastener Gp	1
366-1708	Fastener Gp	1
366-1709	Fastener Gp	1
253-0417	Fixed Axle Fastener Gp	1
8X-1741	Oscillating Axle Fastener Gp	1
266-0893	Drawbar and Bumper Fastener Gp	1 (1)
179-4466	Protective Cap  (1)	1
6V-1867	Clip  (1)	2
6V-1868	Clip  (1)	2
6V-1869	Grommet  (1)	2
6V-7349	Elbow  (1)	1
8T-4186	Bolt  (1)	2
7X-7729	Washer  (1)	2

( 1 )

If Air Start Ar 346-5802

Table 13

Crate 10
Links
261-7524	Bucket Link Gp	1 (1)
261-7526	Bucket Link Gp
261-7528	Bucket Link Gp
273-2282	Bucket Link Gp

Table 14

Crate 11
Tilt Cylinders
358-0434	Tilt Cylinder Ar	1 (1)
358-0435	Tilt Cylinder Ar
358-0436	Tilt Cylinder Ar
358-0437	Tilt Cylinder Ar

Table 15

Crate 12 (2)
Mud Guard Kit
322-2071	Mud Guard Gp	1
366-7713	Machine Fastener Gp	1

( 2 )

Material shipped will depend on optional and mandatory attachments selected.

Table 16

Crate 13 (3)
Unpinned Assembly Kit
367-5441	Hitch Gp	1

( 3 )

Only present when machine is shipped unpinned at the hitch.

Table 17

Crate 14 (2)
Sy-Klone Pre-Cleaner
207-2686	Precleaner Gp	1

Table 18

Crate15
Power Access Ar.
355-2487	Step Gp	1
355-9649	Step Gp	1
362-3423	Platform Mounting Gp	1
366-1414	Operator Lift Wiring Gp	1
367-4314	Platform Gp	1
367-9804	Handrail Gp	1
368-0229	Fastener Gp	1
373-5474	Rear Guard	1
396-3308	Stairway Gp	1

Dimensions and Weights of Components

The shipping configuration of the 994H Wheel Loader is dependent on the destination of the machine and on the transportation that is available. In some instances, the rear frame and the loader frame are shipped separately.

The following table contains the weight of machine components in various shipping configurations.

Show/hide table

Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

Show/hide table

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.

Illustration 2	g02391737

Table 19

Dimensions And Weights of Chassis
Component	Net Weight	Length	Width	Height
(1) Rear Frame	47,700 kg (105,160 lb)	C 7500 mm (295 inch)	2610 mm (103 inch)	A 4591 mm (180 inch)
(2) Shipping Stand	1,270 kg (2,800 lb)
(3) Shipping Stand	4,040 kg (8,906 lb)
(4) Front Frame	All 23,400 kg (51,588 lb) Extended High Lift and Super High Lift 24,800 kg (54,675 lb)	D 3650 mm (144 inch)	2965 mm (117 inch)	B 3630 mm (143 inch)
(5) Shipping Stand	5,190 kg (11,441 lb)

Note: The overall length of the machine is 11,050 mm (435 inch). The overall width of the machine is 2965 mm (117 inch).

Note: Fluids may be added to the machine. The weight of the fluids in the front frame is 712 kg (1570 lb). The weight of the fluids in the rear frame is 1380 kg (3042 lb).

Table 20

Dimensions And Weights of Shipped Machines
Component	Net Weight	Length	Width	Height
Front Axle with Rims	21295 kg (46950 lb)	2055 mm (80 inch)	5435 mm (215 inch)	1930 mm (75 inch)
Rear Axle with Rims	21910 kg (48300 lb)	2055 mm (80 inch)	5435 mm (215 inch)	1930 mm (75 inch)
Left Hand Side Platform	1360 kg (3000 lb)	2490 mm (100 inch)	3405 mm (135 inch)	1270 mm (50 inch)
Right Hand Side Platform	1045 kg (2300 lb)	2565 mm (100 inch)	3405 mm (135 inch)	1270 mm (50 inch)
Cab	1315 kg (2900 lb)	1525 mm (60 inch)	1880 mm (75 inch)	2465 mm (95 inch)
Tire 52/80−57	4520 kg (9965 lb)	3900 mm (155 inch)	1320 mm (52 inch)	3900 mm (155 inch)
Tire 53.5/85−57	5585 kg (12315 lb)	4000 mm (160 inch)	1390 mm (55 inch)	4000 mm (160 inch)
Tire 58/85−57	5690 kg (12550 lb)	3910 mm (155 inch)	1300 mm (50 inch)	3910 mm (155 inch)
ROPS	3785 kg (8350 lb)	2235 mm (90 inch)	2055 mm (80 inch)	2615 mm (105 inch)
Front Fender	975 kg (2150 lb)	3835 mm (150 inch)	2335 mm (90 inch)	1700 mm (65 inch)
Guard Rails	635 kg (1400 lb)	3660 mm (145 inch)	2335 mm (90 inch)	1475 mm (60 inch)
Stairway (Pallet)	N/A	4191 mm (165 inch)	2134 mm (84 inch)	736 mm (29 inch)
Linkage (Extended High Lift)	28213 kg (62200 lb)	7722 mm (304 inch)	2387 mm (94 inch)	2210 mm (87 inch)
Front Axle (Pallet)	21409 kg (47200 lb)	5664 mm (223 inch)	1854 mm (73 inch)	1930 mm (76 inch)
Rear Axle (Pallet)	22407 kg (49400 lb)	56692 mm (2232 inch)	1854 mm (73 inch)	1939 mm (76 inch)
Guardrails (Pallet)	N/A	3683 mm (145 inch)	2336 mm (92 inch)	1524 mm (60 inch)
ROPS	4218 kg (9300 lb)	297100 mm (117 inch)	2133 mm (84 inch)	1955 mm (77 inch)
Cab (Crate)	1542 kg (3400 lb)	2565 mm (101 inch)	2261 mm (89 inch)	2311 mm (91 inch)
Fenders (Crate)	N/A	2159 mm (85 inch)	1346 mm (53 inch)	1600 mm (63 inch)
Right Platform (Pallet)	907 kg (2000 lb)	3048 mm (120 inch)	2438 mm (96 inch)	1219 mm (48 inch)
Left Platform (Pallet)	907 kg (2000 lb)	3048 mm (120 inch)	2438 mm (96 inch)	1219 mm (48 inch)
Chassis
Tire (58/85-15)		3911 mm (154 inch)	3911 mm (154 inch)	1346 mm (53 inch)
Small Crate		1803 mm (71 inch)	1371 mm (54 inch)	812 mm (32 inch)
Large Crate		2438 mm (96 inch)	1371 mm (54 inch)	812 mm (32 inch)
Tilt Cylinder Crate		3505 mm (138 inch)	1447 mm (57 inch)	812 mm (32 inch)
Linkage Crate		2514 mm (99 inch)	1219 mm (48 inch)	838 mm (33 inch)
Cab Stand Bundle		2489 mm (98 inch)	406 mm (16 inch)	381 mm (15 inch)
CIODS Crate
Platform Guard Gp Crate
Walkway Gp Crate

Lift Arrangements Specifications

Note: Specifications are with the 58/85-57 Tires.

Table 21

Extended High Lift Components
Components	Net Weight (kg)	Length (mm)	Width (mm)	Height (mm)
Arm Arrangement (1)	26100	7680	2350	2050
Tilt Links (both) (1)	1180	2350	210	390
Bumper Assembly	11350	2490	4800	990
Tilt Cylinders (one unit)	1030	3290	430	420
Lift Cylinders (one unit)	2140	3040	510	530
Front Chassis (2)	24500
Rear Chassis (3)	47700
Front and Rear Chassis with Shipping Stands (2)	82700

( 1 )	Weight includes new grease line design, rounded up for lifting safety factor.
( 2 )	Includes differences in lift cylinders.
( 3 )	Should be no change between lift arrangements.

Torque Specifications

Table 22

Inch Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Table 23

Metric Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Requirements for the Crane

The 994H Wheel Loader is shipped in several sections. The heaviest section is the loader frame and the rear frame. Two cranes will be required in order to unload this shipping module.

The weights that are listed below include the complete chassis with shipping supports.

• The loader frame and the rear frame for the super high lift machine weigh 83000 kg (182983 lb).

• The loader frame and the rear frame for standard lift and the high lift machines weigh 82000 kg (180779 lb).

• The loader frame and the rear frame for the extended high lift weight 82700 kg (182322 lb)

.

The weights that are listed below include the complete chassis.

• The loader frame and the rear frame for the super high lift machine weigh 72500 kg (159835 lb).

• The loader frame and the rear frame for standard lift and the high lift machines weigh 71500 kg (157630 lb).

• the loader frame and the extended high lift weight 72200 kg (159174 lb)

Note: The loader frame is the heaviest section of the shipping module. Refer to Table 20 in section ""Dimensions and Weights of Components" " in this Special Instruction for the correct weight for the machine configuration.

The capacity of the cranes and the reach of the cranes must be considered because of the width and the height of the Wheel Loader. A spreader bar must be used to lift the rear chassis in order to prevent damage to the hood.

After, the machine is unloaded the larger crane will not be required unless the loader frame and the rear frame are assembled simultaneously.

Table 24

Lifting Dimensions
Description	Dimension
Centerline to side of Rear Frame	1320 mm (50 inch)
Centerline to side of Loader Frame	1345 mm (55 inch)
Centerline to the edge of the axle without the tires	2490 mm (100 inch)
Ground level to the top of the ROPS	6555 mm (260 inch)
Length of the machine with high lift arm assembly and rock bucket	17425 mm (685 inch)
Width of the machine and the loader bucket	5665 mm (225 inch)
Ground level to the top of the hood on the Rear Frame (1)	4570 mm (180 inch)
Ground level to the top of the Loader Frame (2)	4345 mm (170 inch)
Lifting eye to the top of the hood on the Rear Frame	2745 mm (110 inch)
Minimum spreader bar width	2745 mm (110 inch)

( 1 )	The machine should be supported on 1220 mm (48 inch) blocks.
( 2 )	The machine should be supported on 535 mm (20 inch) blocks.

Equipment for Assembly

The following equipment will be required in order to assemble the 994H Wheel Loader.

• Two cranes with an individual capacity of 68100 kg (150135 lb)

• A lift truck with a capacity of 6810 kg (15000 lb)

• Nitrogen Charging Equipment

• One portable air compressor with a capacity of 3 m³ (100 ft³) per minute

• Lifting equipment for personnel with a weight capacity of 225 kg (500 lb) and a height of 6.1 m (20 ft)

• 110 V Generator

• One 2 m (6 ft) ladder and one 2.5 m (8 ft) ladder

• Blocking for the Rear Frame

• Blocking for the Loader Frame

• Guide Bolts

• 5P-0306 Vacuum Transducer

• 5P-3415 Adapter

• 3D-2824 O-Ring Seal

• Paint Remover or Cleaning Solvent

• Lifting Beams, Lifting Slings, Chains, Cables, Shackles and Hooks.

If, the rear frame and the loader frame are attached the blocking for the rear frame should have the following dimensions.

• 910 mm (36 inch) deep

• 1830 mm (72 inch) wide

• 1728 mm (68 inch) tall

Note: The blocking will create clearance for the largest tires and the largest rims on the 994H Wheel Loader. The height of the blocking should be reduced by 305 mm (12 inch) if the machine is equipped with smaller tires.

If, the rear frame and the loader frame are attached the blocking for the loader frame should have the following dimensions.

• 910 mm (36 inch) deep

• 1830 mm (72 inch) wide

• 1220 mm (48 inch) tall

Note: The blocking will create clearance for the largest tires and the largest rims on the 994H Wheel Loader. The height of the blocking should be reduced by 305 mm (12 inch) if the machine is equipped with smaller tires.

Tooling for Assembly

Most the fasteners on the 994H Wheel Loader are metric. Some components on the machine may use standard fasteners. An example of these components may be the engine or the transmission. Machine components will have a single type of fastener.

Required Hand Tools for Assembly

• 1U-7820 Wrench Set

• 8T-5183 Drive Extension

• 4C-9431 Forcing Bolt

• The following sockets will be required for assembly.

Table 25

Thread Size (mm)	Size (mm)	Part Number	Description
8 × 1.25	13	1U-7927	6 Point, 1/2 Inch Drive
10 × 1.25	16	1U-7931	6 Point, 1/2 Inch Drive
12 × 1.75	12 × 1.75	1U-7933	6 Point, 1/2 Inch Drive
16 × 2.00	24	6V-9117	6 Point, 3/4 Inch Drive
20 × 2.5	30	6V-9118	6 Point, 3/4 Inch Drive
20 × 2.5	20	152-1058	12 Point, 3/4 Inch Drive
24 × 3.0	36	6V-9119	6 Point, 3/4 Inch Drive
24 × 3.0	36	4C-6723	6 Point, 1 In Drive
30 × 3.5	46	6V-9120	6 Point, 3/4 Inch Drive
30 × 3.5	46	4C-9812 (1)	No. 5 Spline Drive
30 × 3.5	46	4C-6724	6 Point, 1 In Drive
36 × 4.0	55	8H-8544	12 Point, 3/4 Inch Drive
36 × 4.0	55	4C-8217	6 Point, 1 In Drive

( 1 )

Used for installation of the tires

• The following adapters for the sockets will be required for assembly.

Table 26

Part Number	Description
4C-9813	1 In Female to No. 5 Spline Drive (1)
2P-8261	3/4 Inch Female to 1 inch Male
8H-8561	1/2 Inch Female to 3/4 inch Male

( 1 )

Used for installation of the tires

Required Tooling for Setting Torque

Special Instruction, SEHS7150

• 6V-7820 Torque Multiplier Gp Capacity of 1630 N·m (1200 lb ft)

• 6V-6080 Torque Multiplier Gp Capacity of 4335 N·m (3200 lb ft)

• 9U-7465 Wrench

• 8T-5230 Torque Wrench

• 4C-9814 Reaction Bar

• 6V-3146 Extension

• 6V-4170 Adapter

• A 2 m (6 ft) length of pipe which has an inside diameter that fits the handle of a torque multiplier

• The following torque wrench adapters will be required for assembly.

Table 27

Socket Size (mm)	Part Number
20	262-2758 (1)
24	4C-9563 (2)
30	262-2759 (3)

( 1 )	Used for installation of the drive shafts
( 2 )	Used for installation of the supports at the front of the cab
( 3 )	Used for installation of the mounts on the rear fender

Required Guide Bolts for Assembly

The following guide bolts should be fabricated from metric bolts. Remove the head of the bolt.

Table 28

Diameter (mm)	Part Number	Length
20	8T-4648 (1)	120 mm (4.5 inch)
24	6V-8198 (1)	200 mm (8 inch)
30	8T-6624 (2)	180 mm (7 inch)
36	3E-7441 (3)	440 mm (17.5 inch)

( 1 )	Used for assembly of the loader frame and the rear frame
( 2 )	Used for assembly of the bumper assembly
( 3 )	Used for assembly of the oscillating axle

Required Jacks for Assembly

Assembly of the loader frame and the rear frame will require several jacks. Each jack should be able to support the combined weight of the loader frame and the rear frame. The jacks should have a lifting capacity of 75 to 100 tons.

• 80 ton jack stand gp

ReferenceLift Stand Brochure, NEPH5586. Lift Stand Tool Operating Manual, NEHS0603

Required Lift Eyes and Link Brackets for Assembly

• The following lifting brackets will be required for assembly.

Table 29

Part Number	Size (mm)	Capacity (1)
3E-3882	8	145 kg (315 lb)
4C-8358	10	250 kg (545 lb)
4C-8359	12	410 kg (905 lb)
3E-3879	16	610 kg (1345 lb)
3E-3880	20	990 kg (2185 lb)
3E-3881	24	1585 kg (3490 lb)
9U-5986	30	2475 kg (5455 lb)
9U-5887	48	7600 kg (16755 lb)

( 1 )

Rated Capacity with a 0° Load

• The following link brackets will be required for assembly.

Table 30

Part Number	Capacity	Opening (mm)
138-7573	1020 kg (2250 lb)	10 mm (0.5 inch)
138-7575	1815 kg (4000 lb)	12 mm (0.5 inch)
138-7574	4085 kg (9000 lb)	20 mm (1 inch)
138-7576	4085 kg (9000 lb)	35 mm (1.5 inch)

Required Slings for Assembly

Use two slings in order to mount the tires. The slings will also be required for installation of the following items.

• Lift Arm Pins

• Tilt Cylinders

• Hand Rails

• Fenders

Table 31

Type	Part Number	Width	Length	Capacity of the Choker
Eye and Eye Type III	1U-8256	50 mm (2.0 inch)	2 m (6.0 ft)	2250 kg (4965 lb)
Eye and Eye Type III	1U-8260	75 mm (3.0 inch)	3.0 m (10.0 ft)	3380 kg (7445 lb)

Required Taps and Dies for Assembly

Table 32

Thread Size (mm)	Tap	Die
10 × 1.5	8T-3087	8T-3070
12 × 1.75	8T-3091	8T-3074
16 × 2.0	8T-3096	8T-3078
20 × 2.5	4C-4967	4C-4962
24 × 3.0	4C-4968	−
30 × 3.5	4C-4969	−
36 × 4.0	4C-4970	−

Maintenance Aids

• The sulfuric acid should have a specific gravity of 1.265.

• 9S-3263 Thread Lock Compound

• 4C-5593 Anti-Seize Compound

• 1U-8268 Dry Film Lubricant

• 4C-5599 Anti-Seize Compound

Cleaning

Clean all surfaces on parts before the parts are installed. Remove all burrs and all nicks from parts before the parts are installed. Use 4C-4204 Paint Remover in order to clean mating surfaces. Use 222-3124 Component Cleaner for the final cleaning of mating parts.

Required Equipment for the Commissioning Procedure

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

• JEBD3003 Electronic Technician Software CD and Getting Started Guide

• JERD2093 Cat Common Services

• JERD2124 Electronic Technician Program - Software Only

• JERD2129 Electronic Technician Engine/Machine Subscription

• JERD2137 VIMS Dealer License - Dealers Only

• JERD2138 VIMS Annual Subscription - Dealer

• NEXG4523 Communications Adapter SPM (v1.2)

• 7X-1425 Data Link Cable Assembly

• 7X-1700 Communication Adapter Gp

• 127-9797 VIMS-PC Cable

• 139-4166 Data Link Cable Assembly

Assembly Sequence

The following list is an overview of the assembly process for all of the major components of the machine. The list is only a suggested sequence of assembly. The list only includes steps for assembly of major machine components. Refer to the specific sections in this Special Instruction for detailed assembly procedures.

1. Position the cranes, the blocking, and all of the major components except the loader frame and the rear frame.

2. Position the loader frame and the rear frame on blocking over the rear axle.

3. If the two frames are not attached, pin the loader frame to the rear frame.

4. If the two frames are not attached, install the drive shafts between the loader frame and the rear frame.

5. If the two frames are not attached, install the steering neutralizer valves and the steering neutralizer lines.

6. If the two frames are not attached, connect the steering cylinders. Complete any remaining connections between the rear frame and the loader frame.

7. Install the rear axle and the front axle.

8. Install the drive shafts.

9. Install the tires.

10. Remove all of the blocking and the cribbing from the machine. Remove all of the supports from the chassis.

11. Install all hand rails and toe guards on the bumper, stairway. left platform, right platform, and front walk way.

12. Install the rear bumper assembly.

13. Install the left platform and make all connections to the rear frame.

14. Install the right platform and make all connections to the rear frame.

15. Install the rear stairways.

16. Install the front walk way.

17. Install the front fenders.

18. Install the ROPS and the cab assembly.

19. Complete all connections between the cab and the frame.

20. Install the attachments on the hood.

Note: Before the machine is started, ensure that the following fluid reservoirs are full: hydraulic, engine, pump drive and autolube

21. Start the engine.

22. Install the lift arms and the tilt linkage.

23. Install the tilt cylinders.

24. Install the loader bucket.

25. Install the lighting and the mirrors.

26. Install the guards on the transmission.

27. Check all fluid reservoirs and fill all fluid reservoirs.

28. Complete the commissioning procedure for the machine.

Tips for the Assembly Process

1. Ensure that the appropriate lifting equipment is in place before the machine arrives on the work site. Two cranes will be required in order to unload the complete chassis.

   The weights that are listed below include the complete chassis with shipping supports.

   • The loader frame and the rear frame for the standard lift and high lift machine weigh 77760 kg (171430 lb).

   • The loader frame and the rear frame for the super high lift machine weigh 79800 kg (175930 lb).

   • The loader frame and rear frame for the extended high lift machine weight

   The weights that are listed below include the complete chassis.

   • The loader frame and the rear frame for the standard lift and high lift machine weigh 66450 kg (146500 lb).

   • The loader frame and the rear frame for the super high lift machine weigh 68490 kg (151000 lb).

   • The loader frame and the rear frame for the extended lift machine weigh

   Ensure that the following items can support the machine weight.

   • Chains

   • Spreader Bar

   • Shackles

   • Link Brackets

   • Lifting Eyes

   The weight that is listed below is for the super high lift machine.

   • The weight of a complete machine with a 36 cubic meter (47 cubic yard) coal bucket and the largest tires that are available is 218700 kg (482150 lb).

   • The weight that is listed below is for the extended high lift machine.

   • The weight of a complete machine with a 36 cubic meter (47 cubic yard) coal bucket and the largest tires that are available is 213200 kg (470024 lb)

   The weight that is listed below is for the high lift machine.

   • The weight of a complete machine with a 17.5 cubic meter (23 cubic yard) rock bucket and the largest tires that are available is 203800 kg (449301.55600 lb).

   The weight that is listed below is for the standard lift machine.

   • The weight of a complete machine with a 17.5 cubic meter (23 cubic yard) rock bucket and the largest tires that are available is 203800 kg (449301.55600 lb)

2. Use two cranes in order to unload the machine. Use the following procedure to unload the machine.
   • Position the rear axle and the differential housing.

   • Position the machine over the rear axle.

   • Place supports under the machine.

   The supports under the machine should be high enough that the assembly process can be completed without repositioning the chassis.

3. A crew of five persons will be required in order to assemble the machine.

   1. The assembly process will require four persons and one person will be required to operate the crane.

   2. Two persons should assemble the loader frame and two persons should assemble the rear frame.

4. Separate the assembly process into steps for the loader frame and steps for the rear frame.

   The following list shows the components that must be installed on the loader frame.

   • Front Axle Housing

   • Front Drive Shaft

   • Platform for the Hand Rails

   • Lift Arms

   • Tilt Linkage

   • Tilt Cylinders

   • Front Fenders

   • Tires

   • Loader Bucket

   The following list shows the components that must be installed on the rear frame.

   • Rear Axle Housing

   • Rear Drive Shaft

   • Bumper Assembly

   • Platform

   • Rear Fenders

   • Tires

   • Hand Rails and Ladders

   • Cab

   • ROPS

5. Arrange the work site according to this Special Instruction. Arranging the work site will allow the crane and the service truck to operate.

6. Two packing lists will be included when the machine is shipped.

   1. One packing list will be in a plastic cover on one of the boxes. The other packing list will be inside one of the boxes.

   2. Use the packing list in order to review the parts.

   3. Identify the parts and organize the parts. Refer to the Parts Manual for more information.

7. Install the front axle and the rear axle.

   1. A 55 mm socket is required in order to install the front axle and the rear axle.

   2. The 2P-2338 Socket is a 55.5 mm (2.2 inch) socket.

   3. The new 4C-8217 Socket is a 55 mm (2.2 inch) socket.

   4. When the rear axle is installed, position the axle 152.5 mm (6.0 inch) from the chassis.

Note: Connect the brake lines and the fast fill service group while the axle is in this position. The lines are much easier to connect before the rear axle is installed on the chassis.

8. Use one of the following options in order to install the tires.
   • Tire Handler

   • Lift Truck that is equipped with sideshift

   • Lifting Slings

   Note: Do not install the front fenders or the platform assembly before the tires are installed.

   Note: Install all of the fenders after the tires are installed.

   The front fenders and the rear fenders provide easy access to the machine during the assembly process.

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Illustration 3	g03359010
Lifting eyes for loader frame and lifting eyes for rear frame.

9. Use chains or cables that reach the lifting eyes. The chains or cables should reach lifting eyes (1) on the loader frame and lifting eyes (2) on the rear frame. Use a spreader bar in order to lift the machine off the supports.

10. Use a lift truck that is equipped with hydraulic sideshift in order to install the rear bumper assembly.
    • The lift truck will offer better control of the bumper assembly during the assembly process.

    • The use of a lift truck will provide the operator of the lift truck and the person that is installing the bumper with better communication.

    Note: If the machine is the extended high lift or less, use a lift truck that can lift at least 11200 kg (24692 lb) for the installation of the bumper assembly.

11. Install the access ladders on the bumper assembly. Install the rear fenders. Installing the ladders and the fenders will provide access to the top of the machine.

12. Install the platform assembly.

13. Install all of the hand rails on the following items.
    • Rear Fenders

    • Bumper Assembly

    • Operator Platform

    Note: Do not install the hand rail on the front of the operator platform. Leaving the hand rail off will provide access to the front of the machine for the entire assembly process.

14. Install the lighting to the front fenders before the front fenders are installed on the machine.

15. Use the crane or the boom on the service truck in order to install the hand rails on the hood.

16. Put a box of hand tools on top of the machine. The box of tools will prevent workers from climbing on and climbing off the machine in order to retrieve hand tools.

17. The tilt cylinders are designed to fit the left-hand side of the machine or the right-hand side of the machine. Install each cylinder so that the hydraulic block group faces toward the center of the machine.

18. The installation of the cab to the ROPS is a specific and systematic installation. Be sure to read the procedure in detail before beginning the installation.

19. Torque the bolts for the ROPS to 850 ± 100 N·m (630 ± 75 lb ft).

20. Grease all of the pins in the lift linkage and in the tilt linkage before the machine is moved.

21. Drive the machine to the loader bucket in order to install the loader bucket. Move the lift arms up and down and move the machine forward and backward in order to install the loader bucket.

22. Use a long pipe as a reaction bar when the bolts that hold the tire to the rim are torqued. Use a long pipe that will react with the ground.

23. Refer to the table below in order to have the correct fluid for the machine.
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    Table 33

    Fluid Compartment	Maximum Fluid Amount	Part Number	Part Description
    Cooling System	500.0 L (132.0 US gal)	119-5148	Extended Life Coolant
    Fuel Tank	3912.0 L (1034.0 US gal)	2P-9866	Fuel
    Engine Crankcase	271.0 L (72 US gal)	5P-2586	Oil
    Transmission	388.0 L (103.0 US gal)	2P-9869	Oil
    Differential and Final Drive for the Front and Rear	1240.0 L (328.0 US gal)	5P-1228	Oil
    Differential and Final Drive for the Front and Rear	5000.0 mL (170.0 oz)	5P-2543	Oil
    Hydraulic System with Two Valves	813.0 L (215.0 US gal)	2P-9063	Hydraulic Oil
    Steering and Braking Hydraulic System	267.0 L (71.0 US gal)	2P-9063	Hydraulic Oil
    Brake Cooling Hydraulic System	42.0 L (11.0 US gal)	2P-9063	Hydraulic Oil
    Autolube System	179 L (47.0 US gal)	269-7261	Grease

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Illustration 4	g02391736
Service center

24. Place the parts that are listed in Table 34 onto the machine.
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    Table 34

    Quick Fill Couplers
    Callout	Part Number	Part Description
    1	1Q-5461	Receiver
    2	1Q-5459	Receiver
    3	9S-9271	Male Coupler

25. Use 316-1752 Lifting Device in order to install the collet pins in the lift linkage and in the tilt linkage.

26. The final step in the assembly process should be installation of the rear view mirrors and the hand rail at the front of the platform.

27. The tank for the brake cooling system must be topped off several times. Nine times may be needed in order to fill the system.

28. Dark, dirty oil may leak from the engine at low idle during the early hours of operation. This leaking does not indicate a need for service.

Site Preparation for the Machine

The sight must be level and clear of any debris. Ensure that there is plenty of room for parts, crates, cranes, and machinery.

Illustration 5	g03359016

Table 35

994H Assembly Site Layout Key
Item	Item Description
A	Crane 1 (100 Ton)
B	Crane 2 (100 Ton)
1	Chassis
2	Rear Bumper
3	Front Axle
4	Rear Axle
5	Bucket
6	Cab
7	ROPS
8	Platform
9	Lift Arms
10	Tires/Rims
11	Crate 11 (Tilt Cylinders)
12	Crate 3 (Linkage Pins)
13	Crate 1 (Front Axle Kit)
14	Crate 4 (Engine Install Kit)
15	Crate 5 (Exhaust Expansion Kit)
16	Crate 14 (Sy-Klone Pre-Cleaner)
17	Stairs
18	Hand Rails
19	Crate 7 (Guards/Walkways Kit)
20	Crate 12 (Mud flap Kit)
21	Crate 8A (Lights/Wiring Kit)\Crate 8B (HID Lights)
22	Crate 2 (Rear Axle Kit)
23	Crate 9 (Hardware Kit)
24	Crate 13 (Unpinned Assembly Kit)
25	Crate 10 (Links)
26	Crate 6 (ROPS/Wiring/Sensor Kit)
27	Fenders

Illustration 6	g02656657

The cribbing dimensions for the front of the pinned machine:

• (E) 1016 mm (40 inch) high

• (F) 1270 mm (50 inch) wide

• (G) 1270 mm (50 inch) width per stand

• (H) 2667 mm (105 inch) width overall

The cribbing dimensions for the rear of pinned machine:

• (A) 1676 mm (66 inch) high

• (B) 863 mm (34 inch) wide

• (C) 889 mm (35 inch) width per stand

• (D) 2540 mm (100 inch) width overall

Unloading and Preparation of Machine

The machine will be shipped as pinned or unpinned. If your machine has been shipped as pinned continue below. If your machine has been shipped unpinned continue to ""Procedure for Pinning When Required" "

Note: Use a proper lifting device in order to lift the pinned machine. The weight of the pinned machine is 58966 kg (130000 lb)

Note: Place the rear axle in position so that when unloading the pinned chassis, the chassis can be lowered over the rear axle. If not possible at the work site, Refer to Step 4.

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Illustration 7	g02657479

1. Attach the chains or cables to spreader bar in order to prevent damage to the hood on the rear frame. Attach the chains or cables to the front frame of pinned machine.

2. Lift the pinned machine evenly. Lower the frame onto cribbing.

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Illustration 8	g02656656
Right Hand Side of Rear Frame (A) Rear axle

3. Place rear axle (A) into position on the work site.

   Note: Place a steel plate under the blocking that supports the rear axle. The steel plate should have the following dimensions.

   • 1220 mm (48 inch) wide

   • 2440 mm (96 inch) long

   • 25 mm (1 inch) thick

4. Pull the rear and front axle into position under the chassis.

   Note: Repeat the above step for the front axle using the same steel plate and dimensions.

Lifting the Machine With One Crane

Illustration 9	g01783715
(A) 3.0 m (10 ft) (B) 6.0 m (20 ft) (C) 6.0 m (20 ft) (D) 1.5 m (5 ft)

Six of the slings are 6.0 m (20 ft) long. Two slings are 3.0 m (10 ft) long. Double over two slings in order to achieve length (A). Double over two slings in order to achieve length (D). Use a spreader bar on the end that is attached to the engine end frame.

Procedure for Pinning When Required

The information in this section describes the process for lifting and pinning the machine when shipped separated at the hitch. Continue to "Service Brake Lines (Rear Axle) - Install if the machine was shipped already pinned.

Note: When performing the pinning procedure, install the lower pin first.

Table 36

Item	Qty	Part Number	Part Description
−	−	5P-0960	Molybdenum Grease
−	−	5P-0306	Vacuum Transducer
367-5441 Articulating Hitch Gp
1	2	8R-8510	Slip Joint
2	1	8X-0136	Spacer
3	1	8X-0139	Pin
4	1	8X-0145	Cover
5	1	8X-0146	Terminal Bushing
6	1	8X-0148	Shim Pack
7	1	8X-0149	Pin
8	1	9R-2216	Boss
9	1	134-5788	Shim Pack
10	1	135-6104	Lock Plate
11	1	136-4437	Spacer
12	1	168-1915	Slip Joint
13	1	215-3579	Sleeve
14	2	4D-0514	Pipe Plug
15	1	5H-6822	Bearing
16	2	6V-5845	Bolt
17	8	6V-8132	Bolt
18	12	6V-9167	Bolt
19	6	6v-9667	Bolt
20	1	7X-2549	Bolt
21	8	8t-0281	Bolt
22	4	8T-4121	Hard Washer
23	20	8T-4123	Washer
24	8	8T-4167	Hard Washer
25	1	8T-4223	Hard Washer
26	4	8T-6466	Bolt
27	8	9X-6480	Bolt
348-6060 Automatic Lubrication Lines Gp
33		349-4529	Hose As
8X-0043 Steering Frame Lock
34	1	134-5784	Pin
35	1	1J-2920	Cotter Pin
319-0802 Chassis Harness As
36		8T-5436	Bolt
37		8T-4121	Hard Washer
38		8t-4133	Nut
39		5P-9299	Clip
40		9X-6772	Cable Strap
367-9673 Steering Neutralizer Valve and Mounting
41	4	8T-6466	Bolt
42	4	8T-4121	Hard Washer
367-7804 Machine Fastener Gp
	1	9R-2216	Boss
43	1	215-3579	Sleeve
44	1	5H-6822	Bearing
45	1	7X-2549	Bolt
46	4	8T-4121	Hard Washer
47	1	8T-4223	Hard Washer
48	4	8T-6466	Bolt

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Illustration 10	g02646807

1. Install lip seal (49) onto cap (48)

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Illustration 11	g02646810

2. Install cap (48). Install bolts (47). Connect hose assembly (46) .

   Note: Align cap so that the hole for lubrication in the cap is in the same position as the fitting that is in the upper cap.

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Illustration 12	g02646811

3. Lower the temperature bearing cups (54). Install bearing cup (54). Ensure that bearing cup (54) is seated against the cap.

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Illustration 13	g02646812

4. Install bearing cones (55) .

5. Install the upper bearing cup (54). Ensure that bearing cones (55) are seated correctly.

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Illustration 14	g02646813

6. Install lip seal (53) onto cap (51) .

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Illustration 15	g02646814

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Illustration 16	g02646815

7. Install shims (52) and upper cap (51). Install three of bolts (50), equally spaced. Tighten bolts (50) .

8. Use Tooling (J) to measure the rolling torque of the bearing cones. The rolling torque of the bearing cones must be between 5.5 N·m (50 lb in) and 30 N·m (265 lb in). If the rolling torque is less than 5.5 N·m (50 lb in), remove some of shims (52). If the torque is greater than 30 N·m (265 lb in), add shims (52). Repeat the procedure until the torque falls within the specified range.

   Note: Allow the bearing cups and the bearing cones to reach ambient temperature before measuring the rolling torque.

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Illustration 17	g02646817

9. Install lip seal (42) onto cap (41) .

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Illustration 18	g02646818

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Illustration 19	g02646819

10. Use a suitable lifting device to position cap (41). Install bolts (40). The weight of cap (41) is approximately 31 kg (68 lb).

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Illustration 20	g02646820

11. Lower the temperature of bearing cups (43). Install bearing cup (43). Ensure that bearing cup (43) is seated against the cap.

12. Install bearing cone (44) .

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Illustration 21	g02646821

13. Install spacer (45) and the upper bearing cone (44) .

14. Install upper bearing cup (43). Ensure that there is light contact pressure on the bearing cones.

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Illustration 22	g02646822

15. Install lip seal (39) onto cap (37) .

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Illustration 23	g02646823

16. Install shims (38). Install upper cap (37). Install three of bolts (36). Tighten bolts (36) .

17. Use Tooling (K) to measure the rolling torque of the bearing cones. The rolling torque of the bearing cones must be between 25 N·m (221 lb in) and 75 N·m (55 lb ft). If the rolling torque is less than 25 N·m (221 lb in), remove some of shims (38). If the torque is greater than 75 N·m (55 lb ft), add shims (38). Repeat the procedure until the torque falls within the specified range.

    Note: Allow the roller bearing cups and the roller bearing cones to reach ambient temperature before measuring the rolling torque.

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Illustration 24	g02646824

18. Install bolts (36). Install spacer (35) .

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Illustration 25	g02646825

19. Center a lift truck on the rear of the machine. Attach suitable chains to the lift truck and to the machine in order to position the non-engine end frame and the engine end frame.

20. Slowly move the engine end frame toward the non-engine end frame. Move the stands with the engine end frame. Align the bores of the non-engine end frame with the bores in the engine end frame.

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Illustration 26	g02646826
Lower articulation joint

21. Install Tooling (C) and Tooling (L) .

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Illustration 27	g02646827

22. Install Tooling (M) .

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Illustration 28	g02646830

23. Lower the temperature of pin (34). Use Tooling (N) and a suitable lifting device to install pin (34). The weight of pin (34) is approximately 116 kg (255 lb).

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Illustration 29	g02646831

24. Install cover (29) .

    Note: Ensure that the holes on the top of the pin will be aligned with the holes on the cover.

25. Install bolts (30). Tighten two of the six outer bolts that are 180° apart. Repeat the procedure for the remaining pairs of bolts, then tighten the two inner bolts.

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Illustration 30	g02646833

26. Use Tooling (N) and a suitable lifting device to install pin (32). The weight of pin (32) is approximately 184 kg (405 lb).

27. Remove Tooling (L) .

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Illustration 31	g02646834

28. Remove Tooling (C) .

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Illustration 32	g02646835

29. If the lower pin needs to be rotated, install Tooling (P) on the pin.

    Note: Use a full shim pack to provide proper clearance for the tooling.

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Illustration 33	g02646836

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NOTICE
The groove in the spacer must be up when the spacer is installed. Failure to install the spacer correctly could result in failure of the components.

30. Lower the temperature of spacer (33). Use Tooling (R) to install spacer (33) .

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Illustration 34	g02646837

31. Measure the thickness of lock plate (17) at three locations. Average the measurements and record the result as Dimension (A) .

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Illustration 35	g02646838

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Illustration 36	g02646839

32. Use a suitable lifting device to position lock plate (17). Install four equally spaced bolts (18). Tighten bolts (18) to a torque of 530 ± 70 N·m (390 ± 50 lb ft). Remove bolts (20) .

33. Measure the gap between the frame and the lock plate in several locations around the lock plate. Average the measurements and record the result as Dimension (B). Subtract Dimension (B) from Dimension (A) and record the result as Dimension (C) .

34. Use a suitable lifting device to support lock plate (17). Remove bolts (18) and lock plate (17). Lower lock plate (17) .

35. Install a number of shims (22) that is equal to Dimension (C), minus 0.25 mm (0.001 inch).

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Illustration 37	g02646840

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Illustration 38	g02646841

36. Use a suitable lifting device to position lock plate (17). Install four equally spaced bolts (20). Tighten bolts (20) to a torque of 300 ± 50 N·m (220 ± 35 lb ft). Install two of bolts (18) that are spaced 180° apart. Tighten bolts (18) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

37. Remove two pipe plugs from lock plate (17). Measure the distance from lock plate (17) to pin (25) through the two holes. Average the measurements and record the result as Dimension (D). Subtract Dimension (D) from Dimension (A) and record the result as Dimension (E) .

38. Use a suitable lifting device to support lock plate (17). Remove bolts (20) and bolts (18). Lower lock plate (17) .

39. Install a number of shims (21) that is equal to Dimension (E) ±0.05 mm (±0.0020 inch).

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Illustration 39	g02646842

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Illustration 40	g02646843

40. Use a suitable lifting device to position lock plate (17). Install bolts (20) and bolts (18) .

41. Install the two pipe plugs.

42. Install the wheel chocks on the wheels on the oscillating axle. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".

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Illustration 41	g02646844

43. Lubricate the pins, the roller bearing cups, and the roller bearing cones. Repeat for the upper pin.

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Illustration 42	g02646845

44. Lubricate the pins, the roller bearing cups, and the roller bearing cones. Repeat for the upper pin.

Shims for the Lower Articulation Joint - Install

Note: Allow the pin to return to the ambient temperature before the procedure for shimming or the procedure for torquing is started.

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Illustration 43	g00763445
Cross Section View of Lower Pin for Articulation Joint (J) Gap (2) Pin (5) Plated washer (6) Spacer (9) Locking plate (10) Spacer (11) Bolt (12) Bolt (13) Washer (14) Shim pack (15) Shim pack (16) Plug

1. Tighten four 6V-8132 Bolts (12) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

2. Measure the gap (J) between the loader frame and the 135-6104 Locking Plate (9). Measure the gap around the entire locking plate.

3. Subtract 0.25 mm (0.010 inch) from the minimum thickness of the gap in order to determine the required thickness of the outer shim.

4. Install outer 8X-0148 Shim Pack (14) between the following items: 135-6104 Locking Plate (9) and the loader frame.

5. Tighten four 6V-9167 Bolts (11) to a torque of 300 ± 50 N·m (220 ± 35 lb ft).

6. Install the following items: two 6V-8132 Bolts (12) and two 8T-4167 Hard Washers (13). Install one bolt on one side of the pin and the other bolt on the other side of the pin.

7. Tighten two 6V-8132 Bolts (12) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

8. Measure the gap between the following items: 8X-0139 Pin (2) and 135-6104 Locking Plate (9). Insert a micrometer into the hole (X) in order to measure the gap.

9. Subtract the minimum measurement from the thickness of the 135-6104 Locking Plate (9) that was recorded.

10. Install inner 134-5788 Shim Pack (15) between the following items: 8X-0139 Pin (2) and 135-6104 Locking Plate (9) .

11. Install the following items: eight 6V-9167 Bolts (11) and eight 8T-4123 Plated Washers (5) .

    Note: Use an alternating sequence in order to tighten all 12 6V-9167 Bolts (11) .

12. Tighten 12 6V-9167 Bolts (11) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

13. Install the following items: four 6V-8132 Bolts (12) and four 8T-4167 Hard Washers (13) .

    Note: Use an alternating sequence in order to tighten all eight of the 6V-8132 Bolts (12) .

14. Tighten eight 6V-8132 Bolts (12) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).

15. Install two 4D-0514 Pipe Plugs (16) into two holes (X) .

16. Tighten six 6V-9667 Bolts (8) in the upper articulation joint to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

17. Tighten two 6V-5845 Bolts (4) in the upper articulation joint to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

Complete the Connections between the Frames

Pump Drive Shaft - Install

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Illustration 44	g00763638
Drive Shaft (17) Slip joint (18) Bolt

1. Install 8R-8510 Slip Joint (17) with eight 8T-0281 Bolts (18) .

2. Tighten eight 8T-0281 Bolts (18) to a torque of 290 ± 20 N·m (215 ± 15 lb ft).

Drive Shaft - Install

Illustration 45	g02391857
Front Drive Shaft (19) Slip joint (20) Bolt

1. Install 168-1915 Slip Joint (19) with eight 9X-6480 Bolts (20) .

   Note: Use a 4C-8240 Socket with 12 points in order to tighten the eight bolts to the specified torque.

2. Tighten eight 9X-6480 Bolts (20) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

Steering Frame Lock - Install

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Illustration 46	g01094397
Left Hand Side of Lower Articulation Joint and Steering Frame Lock (24) Pin (25) Cotter pin

1. Connect 8X-0672 Link to the loader frame.

2. Connect the 8X-0672 Link with the following items: 134-5784 Pin (24) and 1J-2920 Cotter (25) .

Wiring Group for the Transmission Control and Power Train Breather Line - Connect

1. Remove caps and remove all hardware used for shipping. Save all hardware and seals. Some hardware and seals will be used in the installation. Take precaution to keep open hydraulic lines free of debris.

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Illustration 47	g02424018
View of Articulation Hitch on Left Hand Side of Machine (1) 319-0802 Chassis Harness As .

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Illustration 48	g02440116

2. Connect the 319-0802 Chassis Harness As (1) to the wiring harness on the rear frame (2).

3. Connect the power train breather 353-8760 Hose As (3) to the pump drive in the rear frame.

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Illustration 49	g02440196

4. Connect the 319-0802 Chassis Harness As (1) and 353-8760 Hose As (3) to the 319-0835 Bracket Assembly (4) located on the rear frame.

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Illustration 50	g02440198

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Illustration 51	g02440399

5. Install two 8T-5436 Bolts (5) and two 8T-4121 Hard Washers (6) through bracket (4) and through the clamp. Install 5P-9299 Clamp (7) to the 353-8760 Hose As (3). Install the clamp over bolt (5) located on the top of the clamp. Install two 8T-4133 Nuts (8) over bolts (5) .

6. Tighten 8T-5436 Bolt (28) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

Power Train Lines - Connect

1. Remove caps and remove all hardware used for shipping. Save all hardware and seals. Some hardware and seals will be used in the installation. Take precaution to keep open hydraulic lines free of debris.

Illustration 52	g02442278

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Illustration 53	g02442357
Close up of connection.

1. Connect the supply for the power train. Remove the cap and connect the 348-2090 Hose As (1) .

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Illustration 54	g02443900

2. Connect the return 348-2087 Hose As (2) to the transmission. Install one 061-9457 O-Ring Seal (3), and one 348-2086 Adapter (4) onto the transmission. Secure with two 8T-3957 Bolts (5). Install one 4J-0527 O-Ring Seal (6) into the Adapter (4). Secure hose (2) to adapter (4). Use four 8T-4183 Bolts (6), and four 8T-4223 Hard Washers (7) .

Oil Cooler Lines - Install

1. Remove caps and remove all hardware used for shipping. Save all hardware and seals. Some hardware and seals will be used in the installation. Take precaution to keep open hydraulic lines free of debris.

Illustration 55	g02424400

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Illustration 56	g02444657

1. Install the two oil cooler lines. Use two 4J-0527 O-Ring Seals (1), four 1P-4582 Half Flanges (2), eight 8T-5412 Bolts (3), and eight 8T-4223 Hard Washers (4) .

Hydraulic Lines - Install

1. Remove caps and remove all hardware used for shipping. Save all hardware and seals. Some hardware and seals will be used in the installation. Take precaution to keep open hydraulic lines free of debris.

Illustration 57	g02424477

1. Install the five hydraulic lines to the front frame. Install the brake oil cooler lines (1), and (2). Install the lube line (3). Install the parking brake line (4). Install the brake line (5)

   Note: Install the lines in order given.

Steering Neutralizer Valve - Install

1. Remove caps and remove all hardware used for shipping. Save all hardware and seals. Some hardware and seals will be used in the installation. Take precaution to keep open hydraulic lines free of debris.

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Illustration 58	g02445516
Steering Neutralizer Valve on Upper Pin for Articulation Joint

1. Install the subassembly for the steering neutralizer valve to the upper plate. Use four 8T-6466 Bolts (1), and four 8T-4121 Hard Washers (2) .

2. Tighten four 8T-6466 Bolts (1) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

Brake Oil Cooler Lines and Service Brake Lines (Rear Axle) - Install

Table 37

367-7950 Service Brake Lines Gp
Item	Qty	Part Number	Description
1	1	8X-4860	Brake Cooling Manifold
2	2	7X-2544	Bolt
3	6	8T-4121	Hard Washer
4	1	262-1941	Tube As
5	1	262-1942	Tube As
367-7944 Brake Cooling Lines Gp
6	1	262-1943	Tube As
7	1	262-1946	Tube As
8	1	271-9069	Tube As
9	1	136-2653	Tube As
10	1	134-2426	Tube As
11	1	262-1945	Tube As
12	1	136-2650	Tube As
13	1	134-2427	Tube As
14	1	164-3306	164-3306
Hardware for Lines & Oil Screens
15	4	1S-0994	Clip
16	4	6K-8178	Clip
17	4	8T-4137	Bolt
18	6	8T-4121	Hard Washer
19	4	8T-4176	Bolt
20	20	8T-4223	Hard Washer
21	4	136-0426	Flange
22	16	8T-4194	Bolt
23	2	114-1374	Support
24	2	6V-8990	Elbow
25	4	6V-9746	O-Ring Seal
26	2	2P-1293	Locknut
27	2	2T-2991	Connector
28	2	4K-1388	O-Ring Seal
29	2	6V-9746	O-Ring Seal

Note: Install the service brake lines before the brake oil cooler lines. The install order will aid in the installation of the service brake lines. The service brake lines are smaller diameter than the brake oil cooler lines.

Brake Oil Cooler Lines (Rear Axle) - Install

Note: Assemble the oil cooler screens before installing the tube assemblies.

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

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Illustration 59	g02463178

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Illustration 60	g02463179

1. Remove the cap from the fitting on the block for the brake oil cooler lines. Connect 262-1943 Tube As (6) to the block. Connect the opposite end of tube assembly (6) to the brake housing.

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Illustration 61	g02463237

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Illustration 62	g02463238

2. Remove the cap from the fitting on the block for the brake oil cooler lines. Connect 262-1946 Tube As (7) to the block. Connect the opposite end of the tube assembly (7) to the bake housing.

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Illustration 63	g02463297

3. Secure tube assembly (6) and tube assembly (7) to the rear axle. Use two 1S-0994 Clips (15) for tube assembly (7) and use two 6K-9178 Clips (16) for tube assembly (6). Secure clip (15) and clip (16) to the rear axle. Use two 8T-4137 Bolts (17), and two 8T-4121 Hard Washers (18) .

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Illustration 64	g02463426

4. Install 114-1374 Support (23) to the rear frame. Use a 8T-4137 Bolt (17), and 8T-4121 Hard Washer (18). Install two 6V-9746 O-Ring Seals (29) into each end of 6V-8990 Elbow (24). Install elbow (24) onto support. Use 2P-1293 Locknut (26) .

   Note: Repeat the step above for the left side of the axle.

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Illustration 65	g02507098

5. Install two 136-0426 Flanges (21) onto each end of the 164-3306 Hydraulic Oil Screen Gp (14). Use eight 8T-4194 Bolts (22), and eight 8T-4223 Hard Washers (20). Install a 4K-1388 O-Ring Seal (28) and a 6V-9746 O-Ring Seal (29) onto 2T-2991 Connector As (27). Install connector assembly into the top and bottom of each flange.

   Note: Repeat the above step for the left hydraulic screen filter.

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Illustration 66	g02463443

6. Install the hydraulic oil screens from Step 5 to the plates on the rear axle. Use two 8T-4176 Bolts (19), and two 8T-4223 Hard Washers (20). Repeat for the other side of the carrier assembly.

   Note: Be sure to install the screens with the direction arrow pointed up.

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Illustration 67	g02463457

7. Connect 271-9069 Tube As (8) to the manifold block and to the top of the hydraulic oil screen. Connect 136-2653 Tube As (9) to the bottom of the hydraulic oil screen and to the elbow. Connect 134-2426 Tube As (10) to the elbow and to the connector on the rear housing.

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Illustration 68	g02463476

8. Connect 262-1945 Tube As (11) to the check valve on the manifold block and to the top of the hydraulic oil screen. Connect 136-2650 Tube As (12) to the bottom of the hydraulic oil screen and to the elbow. Connect 134-2427 Tube As (13) to the elbow and to the connector on the rear housing.

Service Brake Lines (Rear Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

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Illustration 69	g02463019

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Illustration 70	g02463021

1. Install 8X-4860 Block (1) to the rear axle. Use two 7X-2544 Bolts and two 8T-4121 Hard Washers .

2. Remove cap for the service line from the block. Remove cap from brake housing elbow. Connect 262-1941 Tube As (4) to the block. Connect the other end of the tube as (4) to the brake housing.

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Illustration 71	g02463063

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Illustration 72	g02463064

3. Remove cap for the service line from the block and from brake housing fitting. Connect 262-1942 Tube As (5) to the block. Connect the other end of the tube as (5) to the brake housing.

Brake Oil Cooler Lines and Service Brake Lines (Front Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

Table 38

367-7943 Brake Cooling Lines Gp
Item	Qty	Part Number	Description
1	1	136-0445	Manifold
2	1	164-2165	Tube As
3	1	315-6108	Tube As
4	1	315-6107	Tube As
5	1	164-2166	Tube As
6	1	315-6106	Tube As
7	1	315-6105	Tube As
8	1	134-2423	Tube As
9	1	134-2422	Tube As
367-9452 Service Brake Lines Gp
10	1	134-2425	Tube As
11	1	134-2424	Tube As
Hardware for Lines & Oil Screens
12	2	164-3306	Hydraulic Oil Screen Gp
13	4	136-0426	Flange
14	16	8T-4194	Bolt
15	16	8T-4223	Hard Washer
16	1	2T-2991	Connector
17	4	4K-1388	O-Ring Seal
18	4	6V-9746	O-Ring Seal
19		114-1374	Support
20	1	6V-8983	Elbow
21	2	6V-9746	O-Ring Seal
22	2	2P-1293	Locknut
23	1	6V-8997	Union
24	4	8T-4137	Bolt
25	4	8T-4121	Hard Washer
26	2	8T-8513	Clip
27	2	5K-9660	Clip
28	4	8T-4176	Bolt

Note: Install the brake oil cooler lines before the service brake lines group. The install order will aid in the installation of the brake oil cooler lines. The brake oil cooler lines are larger diameter than the service brake lines.

Brake Oil Cooler Lines (Front Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

Illustration 73	g02463596

1. Install the 136-0445 Manifold onto the plate on the front axle. Use four 8T-4137 Bolts (24), and four 8T-4121 Hard Washers (25) .

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Illustration 74	g02464556

2. Install two 136-0426 Flanges (13) onto each end of the 164-3306 Hydraulic Oil Screen Gp (12). Use eight 8T-4194 Bolts (14), and eight 8T-4223 Hard Washers (15). Install a 4K-1388 O-Ring Seal (17) and a 6V-9746 O-Ring Seal (18) onto 2T-2991 Connector As (16). Install the flange and connector assembly into the top and bottom of each flange.

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Illustration 75	g02464596

1. Install the hydraulic oil screens to the plates on the front axle. Use two 8T-4176 Bolts (28), and two 8T-4223 Hard Washers (15). Repeat for the other side of the gear assembly.

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Illustration 76	g02464656

2. Install 114-1374 Support (19) on the right side of the front axle. Use a 8T-4137 Bolt (24), and a 8T-4121 Hard Washer (25). Install two 6V-9746 O-Ring Seals (21) into the 6V-8983 Elbow (20). Install the elbow onto the bracket. Use a 2P-1293 Locknut (22) .

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Illustration 77	g02464677

3. Install 114-1374 Support (19) on the left side of the front bracket. Use a 8T-4137 Bolt (24), and a 8T-4121 Hard Washer (25). Install two 6V-9746 O-Ring Seals (21) into the 6V-8997 Elbow (23). Install the elbow onto the bracket. Use a 2P-1293 Locknut (22)

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Illustration 78	g02464716

4. Connect 164-2166 Tube As (5) to the check valve on the manifold and to the top of the oil screen. Connect 315-6106 Tube As (6) to the bottom of the oil screen and to the elbow. Connect 315-6105 Tube As (7) to the tube assembly and to the brake housing.

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Illustration 79	g02464737

5. Connect 164-2165 Tube As (2) to the check valve on the manifold and to the top of the oil screen. Connect 315-6108 Tube As (3) to the bottom of the oil screen and to the elbow. Connect 315-6107 Tube As (4) to the tube assembly and to the brake housing.

Service Brake Lines (Front Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

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Illustration 80	g02463519

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Illustration 81	g02463520

1. Connect 134-2423 Tube As (8) to the manifold and to the fitting on the spindle on the wheel.

2. Remove the cap from the brake housing.

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Illustration 82	g02463521

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Illustration 83	g02463522

3. Connect 134-2425 Tube As (10) to the manifold and to the fitting on the anchor on the wheel

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Illustration 84	g02463523

4. Install a 5K-9660 Clip (27) to tube assembly (8). Install 8T-8513 Clip (26) to tube assembly (10). Secure two clips to the front axle. Use a 8T-4137 Bolt (24), and a 8T-4121 Hard Washer (25) .

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Illustration 85	g02464900

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Illustration 86	g02464901

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Illustration 87	g02464902

5. Remove the cap from the brake housing. Connect 134-2422 Tube As (9) to the manifold and to the spindle of the wheel. Secure the tube assembly to the front axle. Use a 5K-9660 Clip (27), 8T-4137 Bolt (24), and a 8T-4121 Hard Washer (25) .

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Illustration 88	g02464940

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Illustration 89	g02464941

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Illustration 90	g02464943

6. Remove the cap from the brake housing. Connect 134-2424 Tube As (11) to the manifold and to the spindle of the wheel. Secure the tube assembly to the front axle. Use a 5K-9660 Clip (27), 8T-4137 Bolt (24), and a 8T-4121 Hard Washer (25)

Rear Axle - Install

Table 39

Item	Qty	Part Number	Description
−	−	4C-5599	Anti-Seize Compound
−	−	5P-0306	Vacuum Transducer
−	−	4C-4970	Tap (M36)
245-1315 Fast Fill Automatic Lubrication Service
1	1	148-8422	O-Ring Port Tee
2	1	171-6723	Elbow
247-5923 Grease Lines Gp
3	4	148-8369	Elbow
4	2	8X-5331	Hose Assembly
5	2	8X-5332	Hose Assembly
8X-1741 Oscillating Axle Fastener Group
6	24	9X-2198	Bolt
7	24	3S-6162	Hard Washer

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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 axles are shipped with no fluid.

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Illustration 91	g01124917
Location of Covers for Hydraulic Tanks

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Illustration 92	g02446278
Top View of Hydraulic Tanks (A) Hydraulic tank for braking and steering system (B) Hydraulic tank for brake cooling system

1. Open the covers over the hydraulic tanks. The covers are located on the top of the machine in front of the forward intake system.

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Illustration 93	g01162310
Hydraulic Tank for Braking and Steering System (C) Vacuum transducer

2. Remove the air breather from the hydraulic tank for the steering system. Install vacuum transducer (C) onto the hydraulic tank in order to create a vacuum on the hydraulic system while the rear axle is installed.

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Illustration 94	g01162311
Hydraulic Tank for Brake Cooling System (D) Plug

3. Remove the air breather from the hydraulic tank for the braking system. Install plug (D) into the hydraulic tank.

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Illustration 95	g01122993
Inside View and Right Hand Side of Rear Frame (E) Mounting area for front trunnion of rear axle

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Illustration 96	g01122997
Bottom View and Left Hand Side of Rear Frame (F) Mounting area for rear trunnion of rear axle

4. Clean front machined surface (E) and rear machined surface (F) on the rear frame.

5. Use a ratchet wrench and a 4C-4970 Tap in order to clean the threads of the mounting holes in the rear frame.

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Illustration 97	g01123107
(G) Top view of the front trunnion mount on the rear axle

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Illustration 98	g01123109
(H) Top view of the rear trunnion mount on the rear axle

6. Clean front trunnion mount (G) and rear trunnion mount (H) on the rear axle.

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Illustration 99	g01124700
Right Hand Side of Rear Frame and Positioning of Rear Axle

7. Use two cranes in order to lift the rear axle into position.

8. One crane and a spreader bar can be used in order to lift the rear axle into position.

9. Attach the chains or the cables to a spreader bar in order to prevent damage to the hood.

10. Use the proper lifting device in order to lift the rear axle. The weight of the rear axle is 21910 kg (48300 lb).

11. Lift the rear axle evenly.

12. Lift the rear axle until the gap between the mounting surfaces on the axle and the mounting surfaces on the frame is a maximum of 152 mm (6.0 inch).

    Note: Lifting the axle will aid in the installation of the hose connections for the rear axle.

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Illustration 100	g01132377
Top View and Right Hand Side of Rear Axle (J) Fitting (K) Elbow (L) Fitting (M) Port

13. Connect 289-5506 Hose Assembly to fitting (J) .

14. Connect 252-2650 Hose Assembly to elbow (K) .

15. Connect 273-7251 Hose Assembly to fitting (L) .

16. Connect 349-1608 Hose Assembly to port (M) .

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Illustration 101	g01124918
Top View of Rear Trunnion on Rear Axle (3) Elbow (4) Hose assembly

17. Remove two shipping plugs from the top of the rear trunnion on the rear axle.

18. Install two 6V-8628 Elbows (3) into the top of the rear trunnion on the rear axle.

19. Connect two 8X-5331 Hose Assemblies (4) to the two 6V-8628 Elbows (3) .

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Illustration 102	g01126178
Left Hand Side of Rear Frame and Location of Guide Bolts

20. Align the machined surfaces on the rear axle and the machined surfaces on the rear frame.

21. Use guide bolts and locating dowels in order to position the axle.

    1. Refer to section Guide Bolts that are Required for Assembly in this Special Instruction for information on the fabrication of guide bolts.

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Illustration 103	g01132653
Bottom View and Left Hand Side of Rear Trunnion on Rear Axle (6) Bolt (7) Hard washer

Note: Apply 4C-5599 Anti-Seize Compound to the heads of the bolts and to the threads of the bolts before the bolts are installed.

22. Install the following items to each mounting pad on the rear trunnion of the rear axle: eight 9X-2198 Bolts (6) and eight 3S-6162 Hard Washers (7) .

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Illustration 104	g01054705
Bottom View and Left Hand Side of Front Trunnion on Rear Axle (6) Bolt (7) Hard washer

23. Install the following items to each mounting pad on the front trunnion of the rear axle: four 9X-2198 Bolts (6) and four 3S-6162 Hard Washers (7) .

24. Tighten all of the bolts before removing the lifting devices.

25. Use an alternating sequence in order to tighten all of the bolts. Begin the sequence in the middle of the bolt pattern and work to the outside of the bolt pattern.

26. Tighten the bolts to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft). Turn the bolts for an additional 120 ± 10 degrees.

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Illustration 105	g01126181
Left Hand Side of Rear Frame and Blocking for Rear Axle

27. Place blocking between the rear frame and the axle on both sides of the machine in order to prevent the rear axle from oscillating.

Note: Do not remove the plug and the vacuum transducer from the hydraulic tank. The plug and the vacuum transducer may remain connected for installation of the front axle.

Temperature Sensor (Rear Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

Table 40

365-5976 Sensor Wiring Gp
Item	Qty	Part Number	Description
1	1	3J-1907	O-Ring Seal
2	5	8T-4121	Hard Washer
3	1	8T-4136	Bolt
4	3	8T-4137	Bolt
5	3	8T-4192	Bolt
6	1	8T-4195	Bolt
7	3	8T-4223	Hard Washer
8	1	9X-6772	Cable Strap
9	2	067-2551	Clip
10	1	130-5300	Clip
11	1	154-6626	Bracket As
12	3	160-8708	Bracket As
13	1	204-2281	Cable Strap
14	1	204-8000	Cable Tie Mounting
15	1	288-8390	Temperature Sensor Gp
16	1	319-0798	Sensor Harness As

Note: The axles are shipped with no fluid.

1. Remove the 9S-8004 O-Ring Plug from the bottom of the rear axle.

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Illustration 106	g02446457

2. Install 3J-1907 O-Ring Seal (1) onto 288-8390 Temperature Sensor Gp (15) .

3. Install 288-8390 Sensor (15) into the rear axle .

4. Tighten 288-8390 Sensor (15) to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

5. Fasten the sensor harness to 288-8390 Sensor (15) with 9X-6772 Strap (8) .

   Note: Allow slack in the sensor harness in order to prevent damage to the sensor harness.

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Illustration 107	g02446756

6. Install 160-6708 Bracket (12) to the rear axle in three locations. Use three 8T-4192 Bolts (5), and three 8T-4223 Hard Washers (7) .

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Illustration 108	g02447620

7. Install 154-6626 Bracket As (11) on the top of the front trunnion on the rear axle. Use one 8T-4137 Bolt (4), and one 8T-4121 Hard Washer (2) .

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Illustration 109	g02446458

8. Route 319-0798 Harness (16) next to the brackets.

9. Connect 319-0798 Sensor Harness As (16) to 288-8390 Sensor (15) .

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Illustration 110	g02447717

10. Install 130-5300 Clip (10) to bracket (12). Use one 8T-4136 Bolt (3), and one 8T-4121 Hard Washer (2). Install the 288-8390 Temperature Sensor Gp (15) to clip (10) .

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Illustration 111	g02447877

11. Install the 204-8000 Cable Tie Mounting (14) to bracket (12). Use one 8T-4195 Bolt (6), and one 8T-4121 Hard Washer (2). Secure 319-0798 Sensor Harness As (16) to bracket (12) with a 204-2281 Cable Strap (13) .

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Illustration 112	g02448116

12. Install a 067-2551 Clip (9) around harness (16). Secure harness (16) and clip (9) bracket (12). Use a 8T-4137 Bolt (4), and a 8T-4121 Hard Washer (2) .

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Illustration 113	g02448132

13. Install a 067-2551 Clip (9) around harness (16). Secure harness (16) and clip (9) to 154-6626 Bracket As (11). Use a 8T-4137 Bolt (4), and a 8T-4121 Hard Washer (2)

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Illustration 114	g02448237

14. Connect harness (16) to the machine harness on the rear frame.

Rear Drive Shaft - Install

Table 41

Item	Qty	Part Number	Description
−	−	4C-4967	Tap (M20)
246-6150 Drive Shaft
1	1	252-5660	Drive Shaft
2	8	9X-6480	Bolt

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Illustration 115	g01126189
Machined Surfaces of Drive Shaft (1) Drive shaft.

1. Clean the machined surfaces of 252-5660 Drive Shaft (1) .

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Illustration 116	g01123674
Front View of Rear Axle and Machined Surfaces for Differential Input Yoke

2. Clean the machined surfaces of the differential input yoke on the rear axle.

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Illustration 117	g01123739
Front View of Rear Axle and Retaining Strap for Differential Input Yoke

3. Use a ratchet wrench and 4C-4967 Tap in order to clean the threads of the mounting holes on the differential input yoke.

4. Remove the retaining strap from the differential input yoke.

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Illustration 118	g01126191
Rear View of Transmission and Machined Surfaces for Transmission Output Yoke

5. Clean the machined surfaces on the transmission output yoke that is on the back of the transmission.

6. Use a ratchet wrench and 4C-4967 Tap in order to clean the threads of the mounting holes in the transmission output yoke.

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Illustration 119	g00764417
(1) Drive shaft

7. Use the access area between the rear axle and the transmission in order to position the drive shaft (1) for installation.

8. Use a suitable lifting device in order to lift the drive shaft into position.

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Illustration 120	g01132348
Access Area between Rear Axle and Transmission (1) Drive shaft (2) Bolt

9. Raise 252-5660 Drive Shaft (1) into position. Install eight 9X-6480 Bolts (2) .

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Illustration 121	g01165658
Driveline Components

Note: The drive shaft yokes and universal joints must be aligned with each other after installation.

Note: The drive shaft yoke on the rear axle is mounted on a splined shaft in order to simplify removal and installation of the drive shaft.

10. Tighten eight 9X-6480 Bolts (2) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

    Note: Use a 4C-8240 Socket with12 points in order to tighten the eight bolts to the specified torque.

Front Axle - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

Table 42

Item	Qty	Part Number	Description
−	−	4C-5599	Anti-Seize Compound
−	−	5P-0306	Vacuum Transducer
−	−	4C-4967	Tap (M20)
-	-	4C-8217	Socket (55mm)
253-0417 Fixed Axle Fastener Group
1	8	253-0414	Spacer
2	20	154-1586	Bolt
3	20	8C-4032	Nut
4	32	5T-4896	Spacer
5	4	287-7591	Plate
6	4	287-7592	Plate
104-4751 Drive Shaft
7	4	9X-6480	Bolt

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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 axles are shipped with no fluid.

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Illustration 122	g01092799
Left Hand Side of Loader Frame and Front Drive Shaft (A) Machined surface (B) U-Bolt assembly

1. Clean the machined surfaces on the front drive shaft (A) .

2. Remove the U-bolt assembly (B) from the front drive shaft.

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Illustration 123	g01124908
Top View of Machined Surface on Front Axle Housing (C) Locating dowel (D) Machined surface

3. Clean the locating dowels (C) and the machined surfaces (D) on the front axle.

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Illustration 124	g01124874
Bottom View and Right Hand Side of Loader Frame (E) Machined surface

4. Clean the machined surfaces (E) on the loader frame.

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Illustration 125	g00764811
Front View and Right Hand Side of Loader Frame (F) Mounting surface

5. Clean the 20 mounting surfaces (F) for the spacers.

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Illustration 126	g01132649
Left Hand Side of Loader Frame (J) Front axle

6. Use one crane and a spreader bar in order to lift the front axle into position.

7. Attach the chains or the cables to a spreader bar.

8. Two cranes can be used in order to lift the front axle into position.

9. Use the proper lifting device in order to lift the front axle. The weight of the front axle is 21295 kg (46950 lb).

10. Lift the front axle evenly.

11. Align the machined surfaces on the 8X-0132 Front Axle (J) and the machined surfaces on the loader frame.

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Illustration 127	g01126243
Left Hand Side of Loader Frame Bottom view of drive shaft yoke and drive shaft

Note: There is little clearance between the front axle and the drive shaft. Use caution when the front axle is installed in order to prevent damage to the drive shaft yoke.

12. Use guide bolts and locating dowels in order to position the axle. Refer to section Guide Bolts that are Required for Assembly in this Special Instruction for information on the fabrication of guide bolts.

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Illustration 128	g01337659
Inside View and Top View of Front Axle Fastener (1) Spacer (2) Bolt (5) Plate

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Illustration 129	g02507137
The Bolt Pattern for the Front Axle (1) Spacer (2) Bolt (5) Plate

Note: The fasteners that are used on the inside mounting surface require the thick spacer. The thick spacers are used only on the top mounting surface. The heads of the bolts are marked with an X.

13. Install the following items to the inside mounting holes of the loader frame: eight 253-0414 Spacers (1) and eight 154-1586 Bolts (2) and four 287-7591 Plates ..

    Apply 4C-5599 Anti-Seize Compound before the bolts are installed. Apply 4C-5599 Anti-Seize Compound to the following items.

    • Face of the spacers

    • Heads of the bolts

    • Threads of the bolts

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Illustration 130	g01337670
Outside View and Top View of Front Axle Fastener (2) Bolt (4) Spacer (6) Plate

14. Install the following items to the outside mounting holes of the loader frame: twelve 5T-4896 Spacers (4), twelve 154-1586 Bolts (2) and four 287-7592 Plate .

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Illustration 131	g01124876
Bottom View of Front Axle Fastener (2) Bolt. (3) Nut. (4) Spacer.

15. Install the following items to 20 154-1586 Bolts (2) : twenty 8C-4032 Nuts (3) and twenty 5T-4896 Spacers (4) .

16. Use 4C-8217 Socket in order to tighten all of the nuts before removing the lifting devices from the front axle.

17. Use an alternating sequence in order to tighten all of the bolts. Begin the sequence in the middle of the bolt pattern and work to the outside of the bolt pattern.

18. Tighten the bolts to a torque of 1500 ± 150 N·m (1100 ± 110 lb ft). Turn the bolts for an additional 180 ± 10 degrees.

19. Remove the lifting devices from the front axle.

20. Install a vacuum transducer onto the hydraulic tank in order to create a vacuum on the hydraulic system while the front axle is installed. Refer to section Install the Rear Axle in this Special Instruction.

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Illustration 132	g01125468
Rear View of Front Axle and Brake Cooling Manifold

21. Remove three ORFS caps from the brake cooling manifold on the front axle.

    Note: The brake cooling manifold is located at the top and rear of the front axle.

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Illustration 133	g01125493
Rear View of Front Axle and Brake Cooling Manifold (K) Hose assembly (L) Hose assembly (M) Hose assembly

22. Remove ORFS plugs from the following items.
    • 235-0629 Hose Assembly (K)

    • 235-0631 Hose Assembly (L)

    • 130-7609 Hose Assembly (M)

23. Connect 235-0629 Hose Assembly (K) to the elbow that is located at the top and front of the brake cooling manifold.

24. Connect 235-0631 Hose Assembly (L) to the fitting that is located at the top and rear of the brake cooling manifold.

25. Connect 130-7609 Hose Assembly (M) to the fitting that is located at the bottom and rear of the brake cooling manifold.

26. Remove the plug and the vacuum transducer from the hydraulic tanks.

27. Install the air breathers onto the hydraulic tanks.

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Illustration 134	g01132665
Right Hand Side of Loader Frame and Drive Shaft for Front Axle (5) Bolt

28. Connect the yoke on the axle to the drive shaft yoke. Install four 8T-0281 Bolts (5) .

29. Tighten four 9X-6480 Bolts (5) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

    Note: Use 4C-8240 Socket with 12 points in order to tighten the four bolts to the specified torque.

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Illustration 135	g00764905
Left Hand Side of Loader Frame (N) Shipping support

30. Use a suitable lifting device for the drive shaft before removing shipping support (N) from the loader frame.

31. Remove shipping support (N) from the loader frame.

Temperature Sensor (Front Axle) - Install

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

Table 43

319-0796 Sensor Wiring Gp
Item	Qty	Part Number	Description
1	1	3J-1907	O-Ring Seal
2	2	4D-8123	Clip
3	5	8T-4121	Hard Washer
4	1	8T-4136	Bolt
5	2	8T-4137	Bolt
6	4	8T-4192	Bolt
7	2	8T-4195	Bolt
8	4	8T-4223	Hard Washer
9	1	9X-6772	Cable Strap
10	1	130-5300	Clip
11	4	160-8708	Bracket As
12	2	204-2281	Cable Strap
13	2	204-8000	Cable Tie Mounting
14	1	288-8390	Temperature Sensor Gp
15	1	319-0797	Sensor Harness As

Note: The axles are shipped with no fluid.

1. Remove the 9S-8004 O-Ring Plug from the bottom of the rear axle.

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Illustration 136	g02448716

2. Install 3J-1907 O-Ring Seal (1) onto 288-8390 Temperature Sensor Gp (14) .

3. Install 288-8390 Temperature Sensor Gp (14) into the front axle.

4. Tighten 288-8390 Temperature Sensor Gp (14) to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

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Illustration 137	g02448723

5. Fasten the sensor harness to 288-8390 Temperature Sensor Gp (14) with 9X-6772 Strap (9) .

   Note: Allow slack in the sensor harness in order to prevent damage to the sensor harness.

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Illustration 138	g02448740

6. Install 160-8708 Bracket (11) to the front axle in four locations. Use one 8T-4223 Hard Washer (8), and one 8T-4192 Bolt (6) .

7. Tighten 8T-4192 Bolt (6) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

8. Connect 319-0797 Sensor Harness As (15) to 288-8390 Temperature Sensor Gp (14) .

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Illustration 139	g02448877

9. Install 130-5300 Clip (10) to bracket (11). Use one 8T-4137 Bolt (5), and one 8T-4121 Hard Washer (3). Install the 288-8390 Temperature Sensor Gp (14) to clip (10) .

10. Tighten 8T-4137 Bolt (5) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

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Illustration 140	g02448917

11. Install the 204-8000 Cable Tie Mounting (13) to bracket (11). Use one 8T-4195 Bolt (7), and one 8T-4121 Hard Washer (3). Secure 319-0797 Sensor Harness As (15) to bracket (11) with a 204-2281 Cable Strap (12) .

Guards for the Brake Lines (Front Axle) - Install

Table 44

252-6962 Brake Line Shield Group
Item	Qty	Part Number	Description
1	1	104-2140	Lower Guard (Left Hand Side)
2	4	104-2139	Spacer
3	2	104-2137	Spacer
4	2	103-0010	Bracket
5	1	102-8971	Upper Guard (Left Hand Side)
6	4	8T-5001	Bolt
7	18	8T-4223	Hard Washer
8	8	8T-4192	Bolt
9	6	8T-4139	Bolt
10	4	8T-4136	Bolt
11	6	8T-4121	Hard Washer
12	2	7X-2546	Bolt
	1	104-2138	Lower Guard (Right Hand Side)
	1	102-8970	Upper Guard (Right Hand Side)
250-7503 Guard Assembly
13	3	8T-4223	Hard Washer
14	3	8T-4192	Bolt

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Illustration 141	g01138099
Left Hand Side and Rear View of Front Axle (5) Guard (6) Bolt (7) Hard washer

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Illustration 142	g01138101
Left Hand Side and Inside View of Front Axle (2) Spacer

1. Install 102-8971 Upper Guard (5) to the bosses on the left side of the front axle.

2. Install 102-8971 Upper Guard (5) with the following items: two 104-2139 Spacers (2), two 8T-5001 Bolts (6) and two 8T-4223 Hard Washers (7) .

   Note: Do not tighten the bolts at this time. The loose bolts will aid in the alignment and installation of the guards.

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Illustration 143	g01138100
Left Hand Side and Inside View of Front Axle Housing (3) Spacer (11) Hard washer (12) Bolt

3. Install 102-8971 Upper Guard (5) to the loader frame.

4. Install 102-8971 Upper Guard (5) with the following items: 104-2137 Spacer (3), 8T-4121 Hard Washer (11) and 7X-2546 Bolt (12) .

   Note: Do not tighten the bolts at this time. The loose bolts will aid in the alignment and installation of the guards.

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Illustration 144	g01138102
Left Hand Side and Front View of Loader Frame (4) Bracket (10) Bolt (11) Hard washer

5. Install one 103-0010 Bracket (4) to the boss on the loader frame.

6. Install one 103-0010 Bracket (4) with the following items: 8T-4121 Hard Washer (11) and 8T-4136 Bolt (10) .

   Note: Do not tighten the bolts at this time. The loose bolts will aid in the alignment and installation of the guards.

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Illustration 145	g01138105
Left Hand Side and Front View of Loader Frame (5) Guard (10) Bolt (11) Hard washer

7. Install 102-8971 Upper Guard (5) to 103-0010 Bracket (4) .

8. Install 102-8971 Upper Guard (5) with the following items: one 8T-4136 Bolt (10) and one 8T-4121 Hard Washer (11) .

   Note: Do not tighten the bolts at this time. The loose bolts will aid in the alignment and installation of the guards.

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Illustration 146	g01138103
Left Hand Side and Top View of Front Axle (5) Guard (7) Hard washer (9) Bolt

9. Install 102-8971 Upper Guard (5) to the boss on the front axle.

10. Install 102-8971 Upper Guard (5) with the following items: one 8T-4223 Hard Washer (7) and one 8T-4139 Bolt (9) .

11. Tighten two 8T-5001 Bolts (6) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

12. Tighten 8T-4139 Bolt (9) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

13. Tighten 8T-4136 Bolt (10) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

14. Tighten 7X-2546 Bolt (12) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

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Illustration 147	g01138106
Left Hand Side and Rear View of Front Axle (1) Guard (5) Guard (7) Hard washer (8) Bolt

15. Install 104-2140 Lower Guard (1) to 102-8971 Upper Guard (5) .

16. Install 104-2140 Lower Guard (1) with the following items: four 8T-4223 Hard Washers (7) and four 8T-4192 Bolts (8) .

    Note: Do not tighten the bolts at this time. The loose bolts will aid in the alignment and installation of the guards.

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Illustration 148	g01139994
Left Hand Side and Rear View of Front Axle (1) Guard (7) Hard washer (9) Bolt

17. Install 104-2140 Lower Guard (1) to the bosses on the front axle.

18. Install 104-2140 Lower Guard (1) with the following items: two 8T-4223 Hard Washers (7) and two 8T-4139 Bolts (9) .

19. Tighten 8T-4192 Bolt (8) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

20. Tighten two 8T-4139 Bolts (9) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

21. Install 104-2138 Guard and 102-8970 Guard on the right-hand side of the front axle.

22. Repeat Step 1 through Step 20 for the right-hand side of the front axle.

Guard Assembly for the Temperature Sensor (Front Axle) - Install

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Illustration 149	g01132821
Rear View of Front Axle with Guard Assembly (13) Hard washer (14) Bolt

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Illustration 150	g01132841
Rear View of Front Axle with Guard Assembly (13) Hard washer (14) Bolt

1. Install 250-7503 Guard Assembly in order to protect to 288-8390 Sensor .

2. Install 250-7503 Guard Assembly to the rear of the front axle.

3. Install 250-7503 Guard Assembly with the following items: three 8T-4223 Hard Washers (13) and three 8T-4192 Bolts (14) .

4. Tighten three 8T-4192 Bolts (14) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Tires - Install

Table 45

8X-1316 Rim Mounting Group
Item	Qty	Part Number	Description
1	4	8W-0338	O-Ring Seal
2	4	5T-9796	Connector
3	4	5T-9866	Locknut
4	4	8X-2699	Extension Hose Assembly
5	4	8X-2700	Spud Assembly
6	4	5T-9797	Tire Valve
170-3917 Rim Mounting Group
1	4	8W-0338	O-Ring Seal
2	4	5T-9796	Connector
3	4	5T-9866	Locknut
4	4	170-4689	Extension Hose Assembly
5	4	8X-2700	Spud Assembly
6	4	5T-9797	Tire Valve

Note: The rim mounting group that is required for the machine will depend on the tire size of the machine.

Use one of the following options in order to install the tires.

• Tire handler

• Lift truck that is equipped with sideshift

• Lifting slings

Note: The procedure that is described in this section is the use of a tire handler.

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Illustration 151	g01126181
Left Hand Side of Rear Frame and Blocking for Rear Axle

1. Place blocking between the rear frame and the axle on both sides of the machine in order to prevent the rear axle from shifting.

   Note: The blocking should have a minimum height of 127 mm (5 inch).

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Illustration 152	g01140257
Components for Tire and Rim Assembly

2. Remove the following items from each rim: 8W-0335 Lock Ring , 168-4541 Bead Seat Band and two 104-7203 Flanges or 109-7089 Flanges .

   Note: The flanges that are required for the machine will depend on the tire size of the machine.

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Illustration 153	g01140262
Proper Orientation of Rim Assembly Flange

Note: If the second flange is in the proper orientation, do not remove the flange. Continue the installation process in order to assemble the rim.

3. Reinstall one 104-7203 Flange or 109-7089 Flange .

   Note: The flange that is required for the machine will depend on the tire size of the machine.

Note: Valve Stems and Valve Extensions must be installed during the initial mounting and initial inflation of the tires.

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Illustration 154	g00762850
Valve Stem and Valve Extension (1) 8W-0338 O-Ring Seal (2) 5T-9796 Connector (3) 5T-9866 Locknut (4) 8X-2699 Extension Hose Assembly (5) 8X-2700 Spud Assembly (6) 5T-9797 Tire Valve

Note: The extension hose assembly that is required for the machine will depend on the tire size of the machine.

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Illustration 155	g00765148
Valve Stem and Valve Extension

4. Install the following components to the rim: 5T-9796 Connector (2), 5T-9866 Locknut (3), 8X-2699 Extension Hose Assembly , 170-4689 Extension Hose Assembly (4), 8X-2700 Spud Assembly (5) and 5T-9797 Tire Valve (6) .

   Note: The extension hose assembly that is required for the machine will depend on the tire size of the machine.

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Illustration 156	g01140168
Mounting Area of Tire

5. Clean the mounting area of the tire. Apply a corrosion inhibitor and a lubricant around the tire bead.

   Note: Use corrosion inhibitors and lubricants that are recommended by the tire manufacturer.

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Illustration 157	g01140982
Bead Surfaces on Rim

6. Apply a corrosion inhibitor and a lubricant to the inside bead surface and the outside bead surface of the rim.

   Note: Use corrosion inhibitors and lubricants that are recommended by the tire manufacturer.

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Illustration 158	g02501860
Tire Handler

7. Use a tire handler in order to install the tire onto the rim.

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Illustration 159	g01140426
Rim Assembly Flange

8. Install 104-7203 Flange or 109-7089 Flange to the rim.

   Note: The flange that is required for the machine will depend on the tire size of the machine.

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Illustration 160	g01140434
Assembled View of Rim Assembly Flange

9. Push the flange onto the rim until the 168-4541 Bead Seat Band can be installed.

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Illustration 161	g01140427
Bead Seat Band

10. Install one 168-4541 Bead Seat Band onto the rim assembly.

11. Install one 8W-0338 O-Ring Seal onto the rim assembly.

12. Install one 8W-0335 Lock Ring onto the rim assembly.

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Illustration 162	g01140428
Enlarged View of Components for Bead Seat Band (1) O-Ring seal

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Illustration 163	g01140429
Installation of Driver Key

13. Use a lift truck in order to align the components. Install 8X-2509 Driver Key .

    Note: Inflate the tire to the recommended tire pressure. Consult the tire manufacturer for the recommended tire pressure. Common tire pressure is 87−102 psi in the front tires and 62−73 psi in the rear tires.

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    Table 46

    Location	Tire Size	Ply Rating	Assembly Pressure (1)
    			kPa	PSI
    Front	52/80−57	68 PR	625 Standard Lift 700 High Lift	90 Standard Lift 100 High Lift
    Rear	52/80−57	68 PR	520 Standard Lift 585 High Lift	75 Standard Lift 85 High Lift
    Front	53.5/85−57	76 PR	700	100
    Rear	53.5/85−57	76 PR	585	85
    Front	58/85−57	84 PR	700	100
    Rear	58/85−57	84 PR	585	85

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    ( 1 )

    The tire pressures are listed for reference only.

    Note: Contact a representative of the tire manufacturer in order to determine working pressures.

    Note: Valve Stems and Valve Extensions must be installed during the initial mounting and inflation of the tires.

14. Remove the connector for the tire valve.

15. Repeat Step 2 through Step 13 in order to install the other three tires.

Remove the Blocking from the Chassis

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Illustration 164	g01141155
View of Front Axle and Blocking (B) Hydraulic jacks (D) Front axle (E) Hardwood blocks (F) Blocking

1. Place hydraulic jacks (B) under front axle (D) .

2. Place hardwood blocks (E) between hydraulic jacks (B) and front axle (D) .

3. Lift the loader frame in order to remove blocking (F) .

4. Lower the loader frame to the ground.

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Illustration 165	g01141148
Bottom View of Rear Frame (A) Rear frame (B) Hydraulic jacks

5. Place hydraulic jacks (B) under rear frame (A) .

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Illustration 166	g01141152
Left Hand Side and Rear View of Rear Frame (A) Rear frame (C) Blocking

6. Lift the rear frame (A) in order to remove the blocking (C) .

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Illustration 167	g01126181
Left Hand Side of Rear Frame and Blocking for Rear Axle

7. Remove the blocking that is between the rear frame and the rear axle before the machine is lowered to the ground.

Hand Rails - Install

Note: Assemble all hand rails on the following items before installation.

Hand Rails & Toe Guards for the Draw Bar Assembly - Install

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Illustration 168	g02426656

1. Crib the draw bar up before sub assembly.

Table 47

351-3670 Handrail Gp
Item	Qty	Part Number	Description
1	1	365-3628	Handrail As
2	1	365-3629	Handrail As
246-6241 Handhold Fastener Group
3	4	8T-4139	Bolt
4	8	8T-4121	Hard Washer
5	4	8T-4136	Bolt
6	4	5P-7469	Clip
7	4	5P-7468	Clip
8	4	6V-1874	Grommet
9	2	8T-4185	Bolt
10	2	5P-1076	Hard Washer
11	2	8T-4223	Hard Washer
12	2	8T-4244	Nut
362-7754 Step and Handrail Ar
13	4	358-4867	Tube
14	16	8T-4183	Bolt
15	16	8T-4121	Hard Washer
351-3667 Platform Guard Gp
16	1	365-3630	Guard Plate
17	1	365-3631	Guard Plate
351-3671 Fastener Gp
18	8	8T-4192	Bolt
19	8	5P-1076	Hard Washer
20	4	248-0102	U-Bolt
21	8	5C-7261	Nut
22	8	8T-4224	Hard Washer

1. Crib up bumper before sub assembly.

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Illustration 169	g02449917

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Illustration 170	g02450016

2. Install the 365-3628 Handrail As (1) onto the left side of the bumper in three places. Use four 8T-4139 Bolts (3), and four 8T-4121 Hard Washers (4) on the left side. Use two 8T-4136 Bolts (5), and two 8T-4121 Hard Washers (4) on the back of the bumper.

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Illustration 171	g02450036

3. Repeat Step 3 in order to install 365-3629 Handrail As (2) on the right side of the bumper.

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Illustration 172	g02450058

4. Install two 358-4867 Tubes (13) onto the bumper. Use eight 8T-4183 Bolts (14), and eight 8T-4121 Hard Washers (15) .

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Illustration 173	g02450137

5. Repeat Step 5 in order to install two 358-4867 Tubes (13) onto the right side of the bumper.

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Illustration 174	g02450336

6. Secure handrail (1) to tube (13). Use two 6V-1874 Grommets (8), two 5P-7468 Clips (7), two 5P-7469 Clips (6), one 8T-4185 Bolt (9), one 5P-1076 Hard Washer (10), one 8T-4244 Nut (12), and one 8T-4223 Hard Washer (11) .

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Illustration 175	g02452196

7. Repeat Step 7 in order to secure handrail (2) to tube (13) on the right side of the bumper.

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Illustration 176	g02452216

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Illustration 177	g02452217

8. Install 365-3630 Guard Plate (16) to handrail (1) located on the left side of the bumper. Use four 8T-4192 Bolts (18), and four 5P-1076 Hard Washers (19). Install 365-3630 Guard Plate (16) to handrail (1) located on the back of the bumper. Use two 248-0102 U-Bolts (20), four 5C-7261 Nuts (21), and four 8T-4224 Hard Washers (22) .

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Illustration 178	g02452276

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Illustration 179	g02452277

9. Repeat Step 9 in order to secure 365-3631 Guard Plate (17) to handrail (2) locate on the right side of the bumper.

Draw Bar - Install

Table 48

352-5731 Lift Ar Standard Lift
Item	Qty	Part Number	Description
1	1	352-5607	Bumper Drawbar Ar
8X-1379 Drawbar and Bumper Fastener Gp
2	12	8C-3411	Bolt
3	12	198-4772	Hard Washer

Table 49

352-5732 Lift Ar High Lift
Item	Qty	Part Number	Description
1	1	352-5607	Bumper Drawbar Ar
8X-1379 Drawbar and Bumper Fastener Gp
2	12	8C-3411	Bolt
3	12	198-4772	Hard Washer

Table 50

352-5733 Lift Ar Super High Lift
Item	Qty	Part Number	Description
1	1	352-5608	Bumper and Drawbar Ar
8X-1379 Drawbar and Bumper Fastener Gp
2	8	8T-0370	Bolt
3	8	8C-3411	Bolt
4	16	198-4772	Hard Washer

Table 51

352-5732 Lift Ar Extended High Lift
Item	Qty	Part Number	Description
1	1	352-5609	Bumper Drawbar Ar
8X-1379 Drawbar and Bumper Fastener Gp
2	8	8T-0370	Bolt
3	8	8C-3411	Bolt
4	16	198-4772	Hard Washer

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Illustration 180	g01147039
Bumper Assembly (A) Tape (B) Shipping plugs (C) Mounting surface

1. Remove tape (A) from the fuel level sender.

2. Remove shipping plugs (B) from the fuel tank.

3. Clean the mounting surfaces (C) on the fuel tank.

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Illustration 181	g01147040
Rear View and Left Hand Side of Rear Frame (D) Mounting surface

4. Clean mounting surfaces (D) that are on the rear frame.

5. Use a ratchet wrench and a 4C-4969 Tap in order to clean the threads of the mounting holes in the rear frame.

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Illustration 182	g01147017
Assembled View of Connector Assemblies for Fuel Tank (1) Connector assembly (2) Connector assembly

6. Install the connector assemblies before the fuel tank is installed.

7. Install the following items into the fuel tank: 148-8342 Connector Assembly (1) and 148-8322 Connector Assembly (2) .

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Illustration 183	g01147234
Fuel Lines from Machine (E) Cap

8. Remove caps (E) from the two fuel lines. Refer to Illustration 183.

9. Remove the tie-downs from the fuel lines.

10. Use a lift truck that is equipped with hydraulic sideshift in order to install the rear bumper assembly.
    • The lift truck will offer better control of the bumper assembly during the assembly process.

    • The use of a lift truck will provide the operator of the lift truck and the person that is installing the bumper with better communication.

    Note: If the machine is the super high lift or extended high lift, use a lift truck that can lift at least 12700 kg (28000 lb) for the installation of the bumper assembly.

Note: If chains or cables are used to install the bumper, install guide bolts into the forward hole on each side of the frame. For information on the fabrication of guide bolts, refer to Guide Bolts that are Required for Assembly.

11. Attach the chains or cables to a spreader bar in order to prevent damage to the hood. Attach the chains or cables to two points on each end of the bumper.

12. Lift the bumper and align the mounting holes in the bumper with the mounting holes in the rear frame.

13. Install blocking underneath the bumper. The blocking should be 457 mm (18 inch) high. The blocking should not prevent the bumper from being moved for alignment and installation.

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Illustration 184	g01147023
Installation of Bumper Assembly

14. Use a lift truck that is equipped with sideshift in order to move the bumper assembly into position.

    Note: If your machine is the high lift or the standard lift, you will need 246-6220 Bumper Assembly (4). If your machine is the super high lift, you will need 248-0986 Bumper Assembly .

    Note: If the machine is the super high lift or extended high lift, use a lift truck that can lift at least 12700 kg (28000 lb) for the installation of the bumper assembly.

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Illustration 185	g00766076
Fasteners for Bumper Assembly (8) Bolt (9) Hard washer

15. Lift the bumper. Align the mounting holes in the bumper with the mounting holes in the frame.

Note: DO NOT remove the support of the lift truck or the lifting device until all of the bolts have been tightened with an impact wrench.

16. The bumper assembly for the high lift and the standard lift will require the following items: twelve 8C-3411 Bolts and twelve 198-4772 Hard Washers .

17. Tighten 12 8C-3411 Bolts (8) to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).

18. The bumper assembly for the super high lift will require the following items: four 8T-0370 Bolts , eight 8C-3411 Bolts and twelve 198-4772 Hard Washers .

    Note: Install four 8T-0370 Bolts into the two rear holes on each side of the rear frame.

19. Tighten four 8T-0370 Bolts and eight 8C-3411 Bolts to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).

20. The bumper assembly for the extended high lift will require the following items: four 8T-0370 Bolts , eight 8C-3411 Bolts and twelve 198-4772 Hard Washers .

    Note: Install four 8T-0370 Bolts into the two rear holes on each side of the rear frame.

Note: If chains or cables were used in order to install the bumper, remove the chains or the cables.

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Illustration 186	g01147057

21. Connect 8X-1575 Hose Assembly (F) and 8X-1576 Hose Assembly (G) to the fuel tank.

    Note: If the machine is equipped with a fuel heater, connect 259-3025 Hose Assembly (F) and 259-3024 Hose Assembly (G) .

22. Connect the fuel level sender to buffer (H) for the fuel level.

Step Group For the Draw Bar - Install

Table 52

362-7754 Step and Handrail Ar
Item	Qty	Part Number	Description
1	2	115-3580	Plate
2	2	355-2487	Step Gp
3	2	355-9649	Step Gp
4	4	358-4867	Tube
5	2	4H-1225	Washer
6	22	5P-1076	Hard Washer
7	8	5P-7468	Clip
8	8	5P-7469	Clip
9	8	6V-1874	Grommet
10	16	8T-4121	Hard Washer
11	28	8T-4183	Bolt
12	8	8T-4184	Bolt
13	2	8T-4185	Bolt
14	6	8T-4223	Hard Washer
15	6	8T-4244	Nut

Illustration 187	g03359580
Assembled 355-9649 Step Gp (3)

Sub Assembly of the 355-9649 Step Gp

Table 53

355-9649 Step Gp (3)
Item	Qty	Part Number	Description
16	2	355-2490	Step Support
17	6	356-6693	Plate
18	1	359-1097	Bracket
19	1	359-1098	Bracket
20	4	374-7990	Step As
21	16	8T-0389	Locknut
22	32	8T-4121	Hard Washer
23	8	8T-4182	Bolt
24	4	8T-4196	Bolt
25	4	8T-6466	Bolt

1. Sub assemble the 355-9649 Step Gp (3) .

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Illustration 188	g03359659
(18) 359-1097 Bracket (19) 359-1098 Bracket (20) 374-7990 Step As (21) 8T-0389 Locknut (22) 8T-4121 Hard Washer (24) 8T-4196 Bolt

2. Assemble one 374-7990 Step As (20) to the 359-1097 Bracket (18) and to the 359-1098 Bracket (19). Use eight 8T-4121 Hard Washers (22), four 8T-0389 Locknuts (21), and four 8T-4196 Bolts (24) .

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Illustration 189	g03359588
(16) 355-2490 Step Support (17) 356-6693 Plate (20) 374-7990 Step As (21) 8T-0389 Locknut (22) 8T-4121 Hard Washer (25) 8T-6466 Bolt

3. Assemble two 374-7990 Step As (20) to two 355-2490 Step Supports (16). Use one 356-6693 Plate (17), four 8T-4121 Hard Washers (22), two 8T-0389 Locknuts (21), and two 8T-6466 Bolt (25) at each location. Refer to Illustration 189.

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Illustration 190	g03359940
(16) 355-2490 Step Support (17) 356-6693 Plate (18) 359-1097 Bracket (19) 359-1098 Bracket (20) 374-7990 Step As (21) 8T-0389 Locknut (22) 8T-4121 Hard Washer (25) 8T-6466 Bolt

4. Assemble a 374-7990 Step As (20) through the two brackets (18) and (19) and through Step Supports (16). Use two 356-6693 Plates (17), eight 8T-4121 Hard Washers (22), 8T-0389 Locknuts (21), and four 8T-6466 Bolts (25) .

Installing the 362-7754 Step and Handrail Ar

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Illustration 191	g03359983
(6) 5P-1076 Hard Washer (11) 8T-4183 Bolt

1. Install 355-9649 Step Gp (3) to the bumper assembly. Use four 8T-4183 Bolts (11), and four 5P-1076 Hard Washers (6)

2. Tighten four 8T-4183 Bolts (13) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

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Illustration 192	g03360006
(2) 355-2487 Step Gp (6) 5P-1076 Hard Washer (12) 8T-4184 Bolt

3. Assemble 355-2487 Step Gp (2) to the bumper assembly. Use four 8T-4184 Bolts (12), and four 5P-1076 Hard Washers (6) .

4. Tighten four 8T-4184 Bolts (12) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

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Illustration 193	g03360042
(4) 358-4867 Tube (10) 8T-4121 Hard Washer (11) 8T-4183 Bolt

5. Assemble two Tubes (4) to the machine using eight Bolts (11) and eight Hard Washers (10) .

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Illustration 194	g03361289
(1) 115-3580 Plate (2) 355-2487 Step Gp (4) 358-4867 Tube (7) 5P-7468 Clip (8) 5P-7469 Clip (9) 6V-1874 Grommet (11) 8T-4183 Bolt (14) 8T-4223 Hard Washer (15) 8T-4244 Nut

6. Assemble one Tube (4) to the left-hand rail. Use the hardware shown in Illustration 194.

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Illustration 195	g03361292
(4) 358-4867 Tube (5) 4H-1225 Washer (6) 5P-1076 Hard Washer (7) 5P-7468 Clip (8) 5P-7469 Clip (9) 6V-1874 Grommet (13) 8T-4185 Bolt (14) 8T-4223 Hard Washer (15) 8T-4244 Nut

7. Assemble one Tube (4) to the right-hand rail. Use the hardware shown in Illustration 195.

8. Repeat the above steps for the other side of the bumper.

Platforms

Hand Rails & Toe Guards - Assemble (Left)

Note: Keep platform on the shipping stand for this sub assembly.

Illustration 196	g02664077

Illustration 197	g02664100

Table 54

346-5813 Platform Ar
Item	Qty	Part Number	Description
1	1	347-1818	Operator Platform Gp
351-3670 Handrail Gp
2	1	352-8423	Guardrail As
3	1	352-8138	Guardrail As
4	1	352-8156	Guardrail As
5	2	354-5540	Guardrail As
351-3672 Handrail Fastener Gp
6	16	8T-4136	Bolt
7	16	8T-4121	Hard Washer
8	4	9X-2040	Screw
9	8	8T-4183	Bolt
10	8	5P-1076	Hard Washer
11	8	8T-4223	Hard Washer
12	4	115-3580	Plate
13	8	5P-7469	Clip
14	8	5P-7468	Clip
15	8	8T-4244	Nut
16	8	6V-1874	Grommet
351-3667 Platform Guard Gp
17	1	352-9139	Guard Plate
18	1	352-9140	Guard Plate
19	1	352-9142	Guard Plate
20	1	352-9146	Guard Plate
351-3671 Fastener Gp
21	16	8T-4192	Bolt
22	16	5P-1076	Hard Washer

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Illustration 198	g02452358

1. Install 352-8423 Guardrail As (2) to the left platform. Use six 8T-4136 Bolts (6), and six 5P-1056 Hard Washers (7) .

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Illustration 199	g02452359

2. Install 352-8138 Guardrail As (3) to the left platform. Use six 5P-1056 Hard Washers (7), and six 8T-4136 6 .

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Illustration 200	g02452360

3. Install 352-8156 Guardrail As (4) to the left platform. Use six 8T-4136 Bolts (6), and six 5P-1056 Hard Washers (7) .

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Illustration 201	g02452361

4. Install 352-9139 Guard Plate (17) to handrail (2). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22) .

   Note: Do not install hardware to location (A) .

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Illustration 202	g02452364

5. Install 352-8138 Guard Plate (18) to handrail (3). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22) .

   Note: Do not install hardware to location (B) .

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Illustration 203	g02452366

6. Install 352-9146 Guard Plate (20) to guard (17) and to guard (18). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22)

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Illustration 204	g02452367

7. Install 352-9142 Guard Plate (19) to handrail (4). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22) .

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Illustration 205	g02452570

8. Connect two 354-5540 Guardrail As (5). Use four 9X-2040 Screws (8) .

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Illustration 206	g02452599

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Illustration 207	g02452600

9. Install four 6V-1874 Grommets (16) to guard assemblies (5). Install two 6V-1874 Grommets (16) to handrail (2) and handrail (3). Install one 5P-7468 Clip (14) and 5P-7469 Clip (15) around each grommet (16) .

10. Secure the handrails to each other. Use four 115-3580 Plate (12), eight 8T-4183 Bolts (9), eight 5P-1076 Hard Washers (10), eight 8T-4223 Hard Washers (11), and eight 8T-4244 Nuts (15) .

Hand Rails & Toe Guards - Assemble (Right)

1. Keep platform on the shipping stand for this sub assembly.

Illustration 208	g02664104

Illustration 209	g02664105

Table 55

346-5813 Platform Ar
Item	Qty	Part Number	Description
1	1	347-1816	Operator Platform Gp
351-3670 Handrail Gp
2	1	352-8424	Guardrail As
3	1	352-8138	Guardrail As
4	1	352-8156	Guardrail As
5	2	354-5540	Guardrail As
351-3672 Handrail Fastener Gp
6	16	8T-4136	Bolt
7	16	8T-4121	Hard Washer
8	4	9X-2040	Screw
9	8	8T-4183	Bolt
10	8	5P-1076	Hard Washer
11	8	8T-4223	Hard Washer
12	4	115-3580	Plate
13	8	5P-7469	Clip
14	8	5P-7468	Clip
15	8	8T-4244	Nut
16	8	6V-1874	Grommet
351-3667 Platform Guard Gp
17	1	352-9139	Guard Plate
18	1	352-9140	Guard Plate
19	1	352-9142	Guard Plate
20	1	352-9146	Guard Plate
351-3671 Fastener Gp
21	16	8T-4192	Bolt
22	16	5P-1076	Hard Washer

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Illustration 210	g02452623

1. Install 352-8424 Guardrail As (2) to the right platform. Use six 8T-4136 Bolts (6), and six 5P-1076 Hard Washers (7)

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Illustration 211	g02452624

2. Install 352-8183 Guardrail As (3) to the right platform. Use six 8T-4136 Bolts (6), and six 5P-1076 Hard Washers (7) .

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Illustration 212	g02452625

3. Install 352-8156 Guardrail As (4) to the right platform. Use six 8T-4136 Bolts (6), and six 5P-1076 Hard Washers (7)

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Illustration 213	g02452626

4. Install 352-9139 Guard Plate (17) to handrail (2). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22) .

   Note: Do not install hardware to location (A) .

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Illustration 214	g02452627

5. Install 352-9140 Guard Plate (18) to handrail (3). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22) .

   Note: Do not install hardware to location (B) .

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Illustration 215	g02452628

6. Install 352-9146 Guard Plate (20) to guard (17) and to guard (18). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22)

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Illustration 216	g02452629

7. Install 352-9142 Guard Plate (19) to handrail (4). Use four 8T-4192 Bolts (21), and four 5P-1076 Hard Washers (22)

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Illustration 217	g02453122

8. Connect two 354-5540 Guardrail As (5). Use four 9X-2040 Screws (8)

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Illustration 218	g02453123

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Illustration 219	g02453125

9. Install four 6V-1874 Grommets (16) to guard assemblies (5). Install two 6V-1874 Grommets (16) handrail (2) and handrail (3). Install one 5P-7468 Clip (14) and 5P-7469 Clip (15) around each grommet (16) .

10. Secure the handrails to each other. Use four 115-3580 Plate (12), eight 8T-4183 Bolts (9), eight 5P-1076 Hard Washers (10), eight 8T-4223 Hard Washers (11), and eight 8T-4244 Nuts (15) .

Platform - Install (Right)

Illustration 220	g02432499

Table 56

346-5813 Platform Ar
Item	Qty	Part Number	Description
1	1	347-1816	Platform (Left)
351-1909 Platform Mounting Gp
2	1	347-4385	Support As
366-1709 Fastener Gp
3	8	8T-4194	Bolt
4	8	198-4778	Hard Washer
5	8	8T-4140	Bolt
6	8	198-4780	Hard Washer
7	2	8T-4193	Bolt
8	2	090-8865	Spacer

1. Remove hardware holding the platform to the shipping arrangement.

2. Apply 4C-5599 Anti-Seize Compound to all bolts before installation.

   Note: Do not tighten any bolts until all the bolts for the platform are installed. The loose bolts will aid in the alignment and installation of the platform.

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Illustration 221	g02664140

3. Install 347-4385 Support As (2) to the right side of the rear frame. Use four 8T-4194 Bolts (3), and four 198-4778 Hard Washers (4) .

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Illustration 222	g02664239

4. Attach a suitable lifting device to the platform. Lift the platform into position over the rear frame and the 347-4385 Support As (2). Align the mounting holes in the platform with the mounting holes in the rear frame and support assembly. Use the lift points that marked on the platform in four places.

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Illustration 223	g02672397

5. The above Illustration shows the locations of the three mounting location for the right platform.

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Illustration 224	g02664256

6. Install the platform to the upper hitch assembly. Use four 8T-4140 Bolts (5), and four 198-4780 Hard Washers (6) .

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Illustration 225	g02664317

7. Install the platform to the right rail assembly. Use four 8T-4140 Bolts (5), and four 198-4780 Hard Washers (6) .

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Illustration 226	g02664336

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Illustration 227	g02434376

8. Install the platform to the rear frame at the fire wall. Use two 8T-4193 Bolts (7), and two 090-8865 Spacer (8) .

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Illustration 228	g02664359

9. Install 347-4385 Support As (2) to the right platform. Use four 8T-4194 Bolts (3), and four 198-4778 Hard Washers (4)

10. Torque all bolts to 136 N·m (100 lb ft)

Platform - Install (Left)

Illustration 229	g02432417

Table 57

346-5813 Platform Ar
Item	Qty	Part Number	Description
1	1	347-1817	Platform (Left)
351-1909 Platform Mounting Gp
2	1	347-4385	Support As
366-1709 Fastener Gp
3	8	8T-4194	Bolt
4	8	198-4778	Hard Washer
5	8	8T-4140	Bolt
6	8	198-4780	Hard Washer
7	2	8T-4193	Bolt
8	2	090-8865	Spacer

1. Refer to ""Platform - Install (Right)" " in order to install the left platform.

Cross Member to Connect Platforms - Install

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Illustration 230	g02664496

1. Secure the left and right platforms together. Install 347-1797 Channel As (1) to the left and right platform. Use eight 7X-2553 Bolts (2), and eight 9X-8257 Hard Washers (3)

Rear Stairways

Hand Rails, Toe Guards & Optional Mud Guards - Assemble (Left)

Illustration 231	g02428685

Table 58

358-8242 Stairway Gp
Item	Qty	Part Number	Description
1	1	355-6820	Stairway As
2	1	357-4781	Handrail As
3	1	357-4782	Handrail As
4	2	352-8138	Guardrail As
351-3672 Handrail Fastener Gp
5	28	8T-4138	Bolt
6	30	8T-4121	Hard Washer
7	4	5P-7469	Clip
8	4	5P-7468	Clip
9	4	6V-1874	Grommet
10	2	8T-4183	Bolt
11	2	5P-1076	Hard Washer
12	2	8T-4223	Hard Washer
13	2	8T-4244	Nut
14	1	360-1961	Bracket As
15	2	7X-2393	Conical Bumper
16	2	8T-4137	Bolt
351-3667 Platform Guard Gp
17	2	359-9449	Guard Plate
351-3671 Fastener Gp
18	16	8T-4192	Bolt
19	16	5P-1076	Hard Washer
359-9452 Mud Guard Gp (Optional)
20	1	357-7021	Sheet As
21	1	357-7022	Sheet As
22	1	357-7023	Sheet As
23	1	357-7024	Sheet As
24	1	357-7025	Sheet As
366-7713 Machine Fastener Gp (Optional)
25	58	8T-4136	Bolt
26	58	7X-7729	Washer
27	58	8T-3490	Nut

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Illustration 232	g02454356

1. Install one 357-4781 Handrail As (2), one 357-4782 Handrail As (3), and two 352-8138 Guardrail As (4) to the 355-6820 Stairway As (1). Use 28 8T-4139 Bolts (5), and 28 5P-1076 Hard Washer (6)

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Illustration 233	g02453298

2. Install two 359-9449 Guard Plates (17) to the two guardrail assemblies (4). Use eight 8T-4192 Bolts (18), and eight 5P-1076 Hard Washers (19) .

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Illustration 234	g02453305

3. Secure the handrails together. Use four 6V-1874 Grommets (9), and four 5P-7468 Clamps (8). Use four 5P-7469 Clamps (7) and two 8T-4183 Bolts (10), and two 8T-4244 13 . Use two 5P-1076 Hard Washers (11), and two 8T-4223 Hard Washers (12) .

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Illustration 235	g02454319

4. Install 360-1961 Bracket As (14) to stairway (3), Use two 8T-4137 Bolts (2), and two 8T-4121 Hard Washers (6). Install two 7X-2393 Conical Bumpers to bracket (14) .

Note: Follow the steps below if the optional mud guards are required. If you do have the optional mud guards, continue to ""Rear Stairways - Install (Left)" "

5. Remove 16 knock outs from each side of the stairway assembly.

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Illustration 236	g02507257
Outside of left stairway

6. Install 357-7021 Sheet As (20). Use six 8T-4136 Bolts (25), and six 7X-7729 Hard Washers (26) .

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Illustration 237	g02507338
Outside of left stairway

7. Install 357-7023 Sheet As (22). Use six 8T-4136 Bolts (25), and six 7X-7729 Hard Washers (26) .

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Illustration 238	g02507356
Outside of left stairway

8. Install 357-7022 Sheet As (21). Use four 8T-4136 Bolts (25), and four 7X-7729 Hard Washers (26) .

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Illustration 239	g02507377
Outside of left stairway

9. Secure sheet assembly (21) to sheet assembly (20) and to sheet assembly (22). Use four 8T-4136 Bolts (25), four 7X-7729 Hard Washers (26), and four 8T-3490 Nuts (27) .

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Illustration 240	g02454038
Inside of left stairway

10. Install 357-7024 Sheet As (23). Use six 8T-4136 Bolts (25), and six 7X-7729 Hard Washers (26)

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Illustration 241	g02454436
Inside of left stairway

11. Install 357-7025 Sheet As (24). Use ten 8T-4136 Bolts (25), and ten 7X-7729 Hard Washers (26)

Hand Rails, Toe Guards & Mud Guard (Optional) - Assemble (Right)

Illustration 242	g02428686

Table 59

358-8242 Stairway Gp
Item	Qty	Part Number	Description
1	1	355-6820	Stairway As
2	1	357-4781	Handrail As
3	1	357-4782	Handrail As
4	2	352-8138	Guardrail As
351-3672 Handrail Fastener Gp
5	28	8T-4139	Bolt
6	30	8T-4121	Hard Washer
7	4	5P-7469	Clip
8	4	5P-7468	Clip
9	4	6V-1874	Grommet
10	2	8T-4183	Bolt
11	2	5P-1076	Hard Washer
12	2	8T-4223	Hard Washer
13	2	8T-4244	Nut
14	1	360-1961	Bracket As
15	2	7X-2393	Conical Bumper
16	2	8T-4137	Bolt
351-3667 Platform Guard Gp
17	2	359-9449	Guard Plate
351-3671 Fastener Gp
18	16	8T-4192	Bolt
19	16	5P-1076	Hard Washer
359-9452 Mud Guard Gp (Optional)
20	1	357-7000	Sheet As
21	1	357-7001	Sheet As
22	1	357-7002	Sheet As
23	1	357-7003	Sheet As
24	1	357-7004	Sheet As
366-7713 Machine Fastener Gp (Optional)
25	58	8T-4136	Bolt
26	58	7X-7729	Washer
27		8T-3490	Nut

1. Refer to ""Hand Rails, Toe Guards & Mud Guard (Optional) - Assemble (Left)" " in order to install the hand rails, toe guards & mud guards on the stairway.

Rear Stairways - Install (Left)

Illustration 243	g02507738
Left Stairway

Table 60

358-8242 Stairway Gp
Item	Qty	Part Number	Description
1	1	355-6820	Stairway As
366-1707 Fastener Gp
2	4	8G-0841	Mount As
3	4	5R-5927	Washer
4	4	8T-4648	Bolt
351-3672 Handrail Fastener Gp
5	4	8T-4183	Bolt
6	4	5P-1076	Hard Washer
7	4	8T-4223	Hard Washer
8	4	8T-4244	Nut
9	2	6V-1874	Grommet
10	4	5P-7469	Clip
11	4	5P-7468	Clip
362-7754 Step and Handrail Ar
12	1	115-3580	Plate
13	2	5P-7469	Clip
14	2	5P-7468	Clip
15	2	8T-4183	Bolt
16	2	5P-1076	Hard Washer
17	2	8T-4223	Hard Washer
18	2	6V-1874	Grommet
19	2	8T-4244	Nut

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Illustration 244	g02684240
(A) Lift the stair way evenly

1. Attach the stairway to a suitable lifting device in order to install the following components.

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Illustration 245	g02456578

2. Install two 8G-0841 Isolation Mounts (2) to the upper mounting area on the left platform.

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Illustration 246	g02456558

3. Install two 8G-0841 Isolation Mounts (2) to the bumper.

4. Use a suitable lifting device in order to lift the 355-6820 Stairway As (1) into position. The weight of the stairway assembly is 270 kg (600 lb).

5. Align 355-6820 Stairway As (1) with the mounting holes on the machine.

6. Install the stairway assembly to the bumper with the following items: Use two 8T-4648 Bolts (4), and two 5R-5927 Hard Washers (3) .

7. Install the stairway assembly to the left platform with the following items. Use two 8T-4648 Bolts (4), and two 5R-5927 Hard Washers (3)

8. Tighten four 8T-4648 Bolts .

Rear Stairways - Install (Right)

Illustration 247	g02630940
Right Stairway

Table 61

358-8242 Stairway Gp
Item	Qty	Part Number	Description
1	1	355-6820	Stairway As
366-1707 Fastener Gp
2	4	8G-0841	Mount As
3	4	5R-5927	Washer
4	4	8T-4648	Bolt
351-3672 Handrail Fastener Gp
5	4	8T-4183	Bolt
6	4	5P-1076	Hard Washer
7	4	8T-4223	Hard Washer
8	4	8T-4244	Nut
9	2	6V-1874	Grommet
10	4	5P-7469	Clip
11	4	5P-7468	Clip
362-7754 Step and Handrail Ar
12	1	115-3580	Plate
13	2	5P-7469	Clip
14	2	5P-7468	Clip
15	2	8T-4183	Bolt
16	2	5P-1076	Hard Washer
17	2	8T-4223	Hard Washer
18	2	6V-1874	Grommet
19	2	8T-4244	Nut

1. Repeat Steps 2 through 8 in ""Rear Stairways - Install (Left)" " in order to install the 355-6820 Stairway As in the left side of the machine.

Complete the Connections on the Platforms

Complete Connection Between Platform (Left) and Rear Frame

Note: Some Illustrations may have some parts removed for easier viewing. Some Illustrations may contain parts that have not been installed.

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Illustration 248	g02432916

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Illustration 249	g02432936

1. Connect the lubrication lines to the lubrication pump on the left platform.

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Illustration 250	g02432960
Backside of lube tank

2. Secure lube line (1) to the lube tank. Use one 9X-8250 Clip (3), one 8T-4137 Bolt (4), and one 8T-4121 Hard Washer (5) .

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Illustration 251	g02432961

3. Secure lube line (2) to the lube tank. Use one 9X-8250 Clip (3), one 8T-4137 Bolt (4), and one 8T-4121 Hard Washer (5) .

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Illustration 252	g02433040
Left side of machine. Below left platform

4. Connect the ground for the batteries (6) to the rear frame. Use one 8T-4192 Bolt (7), and one 8T-4223 Hard Washer (8). Secure the ground for the battery to the rear frame. Use one 5P-7462 Clip (9), one 5P-7463 Clip (10), one 6V-0683 Grommet (11), one 8T-4136 Bolt (12), and one 8T-4121 Hard Washer (13) .

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Illustration 253	g02664544
Rear of left platform

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Illustration 254	g02664545
Rear of left platform

5. Install the 319-0801 Chassis Harness As (14) to the left platform. Connect the ground (15) for the harness to the left platform. Use the existing bolt and washer in order to secure the ground wire to the boss.

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Illustration 255	g02664618
Left front corner of the platform

6. Connect the harness assembly from chassis to the left platform. Secure the harness. Remove the existing bolt and washer (16). Install a 130-5300 Clip (17) using the bolt and washer. Install the connection of the harness to the clip.

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Illustration 256	g02664638

7. Secure the power cable for the cab. Remove the existing bolt, washer, and clip from the four bosses on the front chassis. Install the following hardware onto the power cable at each location of the bosses: 8X-5489 Grommet (18), 8T-1888 Clip (19) and 8T-1887 Clip (20) .

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Illustration 257	g02664736

8. Secure the power cable for the cab with out the wire harness at the remaining bosses. Use the following hardware: 8X-5489 Grommet (18), 8T-1888 Clip (19) and 8T-1887 Clip (20)

Complete Connection Between Platform (Right) and Rear Frame

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Illustration 258	g02664870
Rear of right platform

1. Connect the wire harness (A) from the right platform to the chassis. Secure the wire harness with the hardware that is provided on the boss.

2. Steps 1 through Step 3 are for Electric Start machines. Continue to ""Complete Connections for Air Start Machine - Optional" " for machine that use Air Start.

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Illustration 259	g02664797

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Illustration 260	g02664858

1. Connect the power cable (1) from the right platform to the bus on the crossmember. Connect the ground cable (3) from the chassis to the bus on the crossmember. Secure ground cable (3) to the boss on the chassis using the hardware that is on the cable. Route power cable (4) from the left platform along the crossmember and secure the cable to the boss.

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Illustration 261	g02664897

2. Route ground cable (2) from the right platform to left platform along the crossmember. Connect the cable inside of the left platform. Secure cable under existing clamp.

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Illustration 262	g02664964

3. Connect five hoses from the rear chassis to the dryer assembly on the bottom of the right platform.

Complete Connections for Air Start Machine - Optional

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Illustration 263	g02672617
Air start machine only

1. Connect hose (1) to the air tank. Secure hose (10 to the right platform. Use the following hardware:)
   • 8T-4186 Bolt (2)

   • 7X-7729 Washer (3)

   • 6V-1867 Clip (4)

   • 6V-1868 Clip (5)

   • 6V-1869 Grommet (6)

Handrails for the Hood - Install

Table 62

351-3670 Handrail Group
1	1	369-4113	Handrail As Left Hand Side
2	1	365-0713	Handrail As Right Hand Side
3	1	365-0727	Handrail As Left Hand Side
4	1	365-0725	Handrail As Right Hand Side
5	1	365-0742	Handrail As Left Hand Side
6	1	365-0729	Handrail As Right Hand Side
351-3672 Handrail Fastener Group
Item	Qty	Part Number	Description
7	8	264-7654	Bracket Assembly
8	12	8T-4195	Bolt
9	72	8T-4136	Bolt
10	84	8T-4121	Hard Washer
3-11	25	115-3580	Plate
4-12	54	8T-4244	Nut
6-13	52	8T-4223	Hard Washer
7-14	52	8T-4183	Bolt
10-15	52	6V-1874	Grommet
11-16	52	5P-7469	Clip
12-17	52	5P-7468	Clip
13-18	56	5P-1076	Hard Washer

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Illustration 264	g01152389
Top View of Hood and Assembled View of Handrails (3) Handrail (4) Handrail (5) Handrail (6) Handrail

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Illustration 265	g01152051
Enlarged View of Bracket Assembly (7) Bracket assembly (9) Bolt (10) Hard washer

1. Install eight 264-7654 Bracket Assemblies (7) to 365-0727 Handrail (3) and 365-0725 Handrail (4) .

2. Install eight 264-7654 Bracket Assemblies (7) with the following items: 32 8T-4136 Bolts (9) and 32 8T-4121 Hard Washers (10) .

3. Tighten 32 8T-4136 Bolts (9) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

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Illustration 266	g01165096
Bracket Assembly on Right Hand Side of Hood (4) Handrail (9) Bolt (10) Hard washer

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Illustration 267	g01166532
Enlarged View of Bracket Assembly for Hand Rails (4) Handrail (9) Bolt (10) Hard washer

4. Install 365-0725 Handrail (4) to the top and right-hand side of the hood.

5. Install 365-0725 Handrail (4) with the following items: 16 8T-4136 Bolts (9) and sixteen 8T-4121 Hard Washers (10) .

6. Tighten 16 8T-4136 Bolts (9) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

7. Repeat the above steps for the left-hand side of the hood. Substitute the following item.
   • 365-0727 Handrail for 365-0725 Handrail

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Illustration 268	g01152391
Handrail on Right Hand Side and Rear of Hood (6) Handrail (8) Bolt (10) Hard washer

8. Install 365-0729 Handrail (6) to the right-hand side and rear of the hood.

9. Install 365-0729 Handrail (6) with the following items: six 8T-4195 Bolts (8) and six 8T-4121 Hard Washers (10) .

10. Tighten six 8T-4195 Bolts (8) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

11. Repeat the above Steps for the left-hand side of the machine. Substitute the following item.
    • 365-0742 Handrail for 365-0729 Handrail

    Note: DO NOT install 369-4113 Handrail As and 365-0713 Handrail As for the exhaust extensions at this time. This step will provide access to the dust ejectors and the fumes disposal group. Handrails will be installed with the exhaust extensions. Refer to Special Instruction, REHS4997, "994H Wheel Loader Assembly Procedure", "Exhaust Extensions - Install"

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Illustration 269	g02459098
Cross Section View of Fastener Group for Handrail (11) Plate (12) Nut (13) Hard washer (14) Bolt (15) Grommet (16) Clip (17) Clip (18) Hard washer

Note: Be sure to install 5P-1076 Hard Washer (18) onto the slotted holes of 115-3580 Plate (11) .

12. Install 6V-1874 Grommet (15) onto each Handrail.

13. Install 5P-7469 Clip (16) and 5P-7468 Clip (17) onto each grommet.

14. Install 115-3580 Plate (11) onto the back of two 5P-7469 Clips (16) .

15. Install 115-3580 Plate (11) with the following items: two 8T-4244 Nuts (12), two 8T-4223 Hard Washers (13), two 8T-4183 Bolts (14) and two 5P-1076 Hard Washers (18) .

    Note: Position the fastener groups for proper alignment before tightening the fasteners for the locations of the fastener groups.

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Illustration 270	g02459137
Fastener Group for Handrails on Platform (18) Hard washer

16. The clips will be facing toward each other for the Handrails on the platform.

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Illustration 271	g02459161
Fastener Group for Handrails on Hood and Platform (18) Hard washer

17. Refer to Illustration 271 for the proper alignment of the fastener groups for the hood and the platform.

    Note: The clips will be facing toward each other.

18. Repeat Step 12 through Step 15 for the remaining fasteners.

    Note: The fastener groups will usually be positioned toward the middle of the Handrail. All of the fasteners are marked with an X.

Cab/ROPS Install - Chassis Preparation

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Illustration 272	g02656417

1. Remove brake valve (A) from shipping 346-3969 Support As by removing four bolts and four washers. Remove the shipping support assembly. Discard the shipping support. Save all hardware for the brake valve. Save the cab mounts and cab mount hardware.

   Note: Do not disconnect the hydraulic lines from the manifold. Let assembly hang. Save all hardware.

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Illustration 273	g02656418

2. Remove 346-3969 Support As (B) from shipping brackets. Save all the bolts and hard washers from the support assembly (B) .

3. Remove two shipping 366-1720 Bracket Assemblies (2) that connects the support assembly to the frame. Discard the shipping brackets and hardware. Safely lower the support Assembly to the ground.

   Note: Support assembly to be used in the following section ""Attaching the Cab to the ROPS" ".

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Illustration 274	g02665076

4. Remove the fill tube (C) from bracket (D) for the screens. Retain the hardware.

5. Remove bracket (D) for the screens and the diagnostic lines from the shipping bracket (E). Retain the hardware

   ReferenceRefer to Illustration 274.

6. Remove the shipping bracket (E) from chassis and discard the bracket and hardware.

   ReferenceRefer to Illustration 274.

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Illustration 275	g02665156

7. Install 347-1781 Channel (3) to the left and right platforms using the following hardware:
   • Eight 7X-2553 Bolts (1)

   • Eight 9X-8257 Washers (2)

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Illustration 276	g02665199

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Illustration 277	g02665225
Arrows indicate existing hardware and location

8. Install bracket (D) for the screens and install the diagnostic assembly onto channel (3). Use the existing hardware for the bottom mounting. Use the following hardware on the side of bracket (D) :
   • Four 8T-4956 Bolts (4)

   • Four 5P-1076 Hard Washers (5)

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Illustration 278	g02665236

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Illustration 279	g02665237
Arrows indicate existing hardware and location on channel assembly

9. Install four air lines (F) from the left and right platforms for the air system along channel (3). Connect the lines to the fittings at the center of channel (3). Secure the lines with the existing hardware on channel (3.)

Build Cab Stand and Position Cab/ROPS

Select a location near chassis in order to build the cab stand and assemble the ROPS to the cab. The area should be as level as possible. The area should be approximately 3048 mm (10 ft) long by 3048 mm (10 ft) wide.

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Illustration 280	g02665256
Completed cab stand

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Illustration 281	g02655497
(A) 199.4 mm (8 inch) (B) 383.4 mm (15 inch) (C) 1096.4 mm (43 inch) (D) 1280.4 mm (50 inch) (E) 2438.4 mm (96 inch) (F) 324 mm (13 inch) (G) 140 mm (5.5 inch) (H) 2438 mm (96 inch)

1. Build the cab stand using the included cribbing material and bolts to the dimensions in Illustration 298. The completed stand should look like Illustration 297.

   Note: The cribbing has been labeled for ease of assembly. Match the corresponding letters. Example: A to A, B to B.

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Illustration 282	g02665637
(A) 288 mm (11 inch) (B) 250 mm (10 inch)

2. Place the cab on the wood stand per the dimensions.

   Note: Location of the cab on the wood stand is important. The ROPS will line up correctly for the subassembly. Refer to ""Attaching the Cab to the ROPS" ".

3. Position ROPS on level ground 914 mm (3 ft) behind the cab.

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Illustration 283	g02672698

4. Remove the shipping hardware from the ROPS that consists of three brackets.

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Illustration 284	g02655519
Arrows indicate areas to be cleaned

5. Clean all machined ROPS surfaces.

Attaching the Cab to the ROPS

Note: Ensure that you read and understand the following instruction. Do not skip any steps or take any short cuts. Ensure that the ROPS will line up correctly for the Cab/ROPS subassembly.

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Illustration 285	g02430718

1. Remove the rear panel assembly from the cab that encloses the HVAC unit. Save all covers and hardware.

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Illustration 286	g02586377
Rear view of cab

2. Remove two covers (A) for the cab mounts (four bolts per cover). Save all covers and hardware.

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Illustration 287	g02586379

3. In the cab, move the floor mat so that access can be gained to the front cab mount covers in the Illustration above.

4. Remove the covers (B) for the front cab mounts (four bolts per cover). Save all covers and hardware.

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Illustration 288	g02430722

5. On the front roof of the cab, remove the covers for the wiper motors and remove the entire wiper motor assembly (motor and arm). Save the hardware and covers.

6. The steps below are important in this procedure. Follow carefully.

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Illustration 289	g02665658

7. Install the 346-3969 Support As with mounts to the ROPS. The bosses and the plate should face the front of the ROPS. Use the previous two 7X-2554 Bolts (1) and two 198-4780 Hard Washers (2) from ""Cab/ROPS Install - Chassis Preparation" " in each side of the support assembly and into the ROPS pad. Torque the bolts in the cab mount support assembly to 240 ± 40 N·m (170 ± 30 lb ft).

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Illustration 290	g02665657

8. Place nine of the bolt assemblies in each of the 350-8891 Brackets (4). Install 18 7X-0593 Hard Washers (1) followed by 18 118-5584 Spacers (2) onto 18 3E-9850 Bolts (3) .

   Note: Secure the last bolt to the bracket with a tie-strap. This action will ensure that the bolts do not slip during the lift procedure.

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Illustration 291	g02672756

9. Attach chains or cables to the ROPS in four places. Use a suitable lifting device in order to lift ROPS. The weight of the ROPS is 4218 kg (9300 lb).

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Illustration 292	g02665696

10. Position the ROPS behind the cab.

    Note: Adjust the lifting device in order to lift the ROPS evenly.

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Illustration 293	g02665698

11. Move the ROPS toward the front of the cab.

    Note: Use caution when the ROPS is moved into position in order to prevent damage to the wiring harnesses for the ROPS lighting and the cab washer lines. The wiring harnesses are attached to the ROPS and to the cab.

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Illustration 294	g02665717

12. Install a 8T-4141 Bolt and a 086-0299 Washer into the cab mount. These bolts should only be hand tightened until the cab is mounted to the machine. Repeat for the other rear mount.

Front Lifting Assembly for the ROPS and Cab Install

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Illustration 295	g02655738

1. Install a 350-8890 Tube (3) through the two U-shaped brackets on top of the cab. Place the other 350-8890 Tube (3) on top of the ROPS structure in line with the tube on top of the cab. Ensure that the tube is flush with the top of the cab

   Note: Place card board or other material between the tube and the cab.

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Illustration 296	g02691677

2. Install two 266-8990 Threaded Rod (4) through each tube (3). Install a 7X-0585 Hard Washer (1) and a 299-3423 Nut (2) onto each of the 266-8990 Threaded Rod (3) .

   Note: Ensure the harness for the ROPS is clear of hardware and tubes.

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Illustration 297	g02691678
Front view of lift assembly shown attached to cab and ROPS

3. Run the nuts (2) down equal distances on each rod. Tighten the nuts on the rods.

4. Use a ratchet wrench and tap in order to clean the threads of the mounting holes in the rear frame for the ROPS.

5. Clean the ROPS mounting surface on the rear frame. The surface should be free of paint or grease, and should be clean and dry when the ROPS is installed.

Cab/ROPS- Install

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Illustration 298	g02665776
Arrows indicate correct lifting points

1. Use a suitable lifting device in order to lift the ROPS and the cab together as an assembly.

   Note: The weight of the ROPS and the cab assembly is 51260 kg (11300 lb).

2. Apply tension to the lifting device before removing the assembly from the stand and ensure that the lifting devices are not in a bind. Lift the assembly evenly from the stand. Lift the cab and ROPS assembly into position on the machine using your suitable lifting device.

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Illustration 299	g02456895

3. Continue lowering the cab onto to the machine.

   Note: Ensure all air, grease, and electrical lines are clear before lowering the cab and ROPS assembly onto the frame.

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Illustration 300	g02665796

4. Install 21 7X-0593 Hard Washers (1), 118-5584 Spacers (2), and 3E-9850 Bolts (3) into the ROPS mount. Repeat for the other side.

   Note: Hand-tighten the bolts until the ROPS is in the correct location.

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Illustration 301	g02672878

5. Remove the 350-8891 Bracket from each ROPS mount and install the nine bolt assemblies.

   Note: Verify the cabs location with respect to the machine ROPS.

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Illustration 302	g02672904

6. Install the bolt and washer into the front cab mounts that were removed in Step 1 of the ""Cab/ROPS Install - Chassis Preparation" " section.

7. Torque the front cab mount bolts to 460 ± 60 N·m (340 ± 44 lb ft).

8. Install the cover plates for the front cab mounts and install the floor mat

9. Torque the rear cab mount bolts to 460 ± 60 N·m (340 ± 44 lb ft).

10. Install the cover plates for the rear cab mounts

11. Torque the 60 ROPS bolt assemblies to 850 ± 100 N·m (627 ± 74 lb ft).

    Note: Note: DO NOT apply any anti-seize compound to the bolts for the ROPS.

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Illustration 303	g02665830

12. Remove the nuts and washers from the 266-8990 Threaded Rod . Remove the rods and the 350-8890 Tube from the cab.

13. Remove lifting chains once all components are aligned and all mounting hardware is installed.

14. Install the wiper motor assembly (motor and arm) and the cover using the existing hardware. Refer to Step 5 of the ""Attaching the Cab to the ROPS" ".

Cab Connections

Remove shipping caps and bags.

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Illustration 304	g02665836

1. Install the valve for the brakes (1) to the bottom of the cab. Use the existing hardware.

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Illustration 305	g02665880
Bottom left side of cab

2. Remove the plug from the four lines for the steering control. Connect the four lines for the steering control to the steering manifold on the bottom of cab.

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Illustration 306	g02666118

3. Install the brake manifold onto the bottom of the crossmember for the cab and ROPS. Use the existing hardware.

   Note: A suitable lifting device may be needed in order to lift the manifold into place.

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Illustration 307	g02666137
Back of cab

4. Connect the Cab harness to the ROPS harness. Install the connected harnesses into the clip.

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Illustration 308	g02665917
Back right of cab

5. Route the harness from the rear frame up through the bottom opening on the right side of the cab. Connect the machine harness from the rear frame in five places at the back of the cab.

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Illustration 309	g02665937
Back right of cab

6. Connect the camera and power cable for the cab. Use the hardware supplied on the connector in order to install the power cable for the cab.

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Illustration 310	g02665986

7. Secure the machine harness to the cross member below the cab. Use the supplied hardware. Secure the power cable for the cab. Use the following hardware:

   Note: There are two bands of green tape on the power cable for the cab. Ensure that the first band is clamped at this location. This procedure will ensure that the cable has room to move during machine operation. The second green band will be clamped inside of the cab.

   • (1) 8X-5489 Sleeve

   • (2) 8T-1887 Clip

   • (3) 8T-1888 Clip

   • (4) 8T-4137 Bolt

   • (5) 8T-4121 Hard Washer

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Illustration 311	g02666016
Bottom inside of cab in the back

8. Secure the machine harness in two places and secure power for the cab in side of the cab. Use the following hardware:
   • 8T-4136 Bolt (6)

   • 8T-4121 Hard Washer (7)

   • 8T-7529 Clip (8)

   • 8T-1887 Clip (9)

   • 8T-1888 Clip (10)

   • 8X-5489 Sleeve (11)

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Illustration 312	g02666040

9. Secure the machine harness onto two bosses in the cab. Use the following hardware:
   • 8T-4136 Bolt (12)

   • 8T-4121 Hard Washer (13)

   • 204-8000 Cable Tie Mounting (14)

   • 204-2281 Cable Strap (15)

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Illustration 313	g02666056
Rear of cab. Wire harness has been removed from picture for easier viewing. (A) Supply hose (B) Return hose (AA) Band clamps

10. Remove the shipping caps from the tubes for the heater connections at the rear of the cab. Remove the shipping plugs from the heater hoses. Connect the hoses. Install the using two 5D-1026 Band Clamps (AA) .

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Illustration 314	g02673049

11. Secure the heater hoses to the cab support (C) under the cab, next to the brake manifold. Use the existing bracket (D) that is attached to the heater hoses (E) and use the existing bracket (F) that is attached to the harness. Use following hardware:
    • 8T-4136 Bolt (16)

    • 8T-4121 Hard Washer (17)

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Illustration 315	g02673119

12. Secure the heater hoses (E) at the second location at the cross member (G) between the platforms. Use the existing clamp (H). Use the following hardware:
    • 8T-4136 Bolt (18)

    • 8T-4121 Hard Washer (19)

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Illustration 316	g02666096

13. Connect the two lines for the air conditioner.

Platform Covers - Install

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Illustration 317	g01172526
Front View of Sheet Assembly for ROPS and Cab on Right Hand Side of Platform (1) Sheet (3) Bolt (4) Hard washer

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Illustration 318	g01172531
Rear View of Sheet Assembly for ROPS and Cab on Right Hand Side of Platform (1) Sheet (3) Bolt (4) Hard washer

1. Install 351-7947 Cover (1) to the right-hand side of the platform. Refer to Illustration 317 and Illustration 318.

2. Install 351-7947 Cover (1) with the following items: six 8T-4136 Bolts (3) and six 8T-4222 Hard Washers (4). Refer to Illustration 317 and Illustration 318.

3. Tighten six 8T-4136 Bolts (3) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 317 and Illustration 318.

4. Repeat Step 1 through Step 3 for the left-hand side of the machine. Substitute the following item.
   • 351-7947 Cover for 352-2205 Cover

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Illustration 319	g01172533
Rear View of Cab and Plate Assembly on Platform

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Illustration 320	g01172535
Enlarged View of Plate Assembly on Platform

5. Install 351-7948 Cover (5) onto the platform at the rear of the cab. Refer to Illustration 319 and Illustration 320.

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Illustration 321	g02462458

6. Install 351-7948 Cover (5) Use ten 8T-4136 Bolts (7), and ten 8T-4222 Hard Washers (8) .

7. Tighten six 8T-4137 Bolts (3) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 319 and Illustration 320.

Front Walk Way - Assemble

Illustration 322	g02430978

Table 63

351-3692 Walkway Gp
Item	Qty	Part Number	Description
1	1	344-2064	Walkway As
2	1	351-3319	Sheet
3	1	344-2063	Walkway As
351-3666 Platform Mounting Gp
4		8T-4956	Bolt
5		5P-1076	Hard Washer
6		8T-4244	Nut

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Illustration 323	g02431038

1. Secure 344-2064 Walkway As (1), 351-3319 Sheet (2), and 344-2063 Walkway As (3) together. Use four 8T-4956 Bolts (4), four 5P-1076 Hard Washers (5), and four 8T-4244 Nuts (6) .

Hand Rails & Toe Guards Assemble

Illustration 324	g02431116

Table 64

351-3670 Handrail Gp
Item	Qty	Part Number	Description
1	2	362-0951	Handrail As
2	1	362-0949	Handrail As
351-3666 Platform Mounting Gp
3	12	8T-4139	Bolt
4	12	8T-4121	Hard Washer
5	4	6V-1874	Grommet
6	4	5P-7468	Clip
7	4	5P-7469	Clip
8	2	8T-4183	Bolt
9	4	8T-4223	Hard Washer
351-3667 Platform Guard Gp
10	1	362-8232	Guard Plate
11	1	362-8233	Guard Plate
12	1	362-8234	Guard Plate
351-3671 Handrail Fastener Gp
13	10	8T-4192	Bolt
14	10	5P-1076	Hard Washer

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Illustration 325	g02454656

1. Install two 362-0951 Handrail Assemblies (1). Use eight 8T-4139 Bolts (3), and eight 8T-4121 Hard Washers (4) .

2. Install 362-0949 Handrail As (2). Use four 8T-4139 Bolts (3), and four 8T-4121 Hard Washers (4) .

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Illustration 326	g02454657

3. Secure both handrails (1) to handrail (2). Use four 6V-1874 Grommets (5), four 5P-7468 Clips (6), four 5P-7469 Clips (7), two 8T-4183 Bolts (8), and four 8T-4223 Hard Washers (9) .

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Illustration 327	g02454799

4. Install 362-8232 Guard Plate (10) to handrail (2). Use four 8T-4192 Bolts (13), and four 5P-1076 Hard Washers (14) .

5. Install 362-8233 Guard Plate (11) to handrail (1). Use four 8T-4192 Bolts (13), and four 5P-1076 Hard Washers (14) .

6. Install 362-8234 Guard Plate (12) to handrail (1). Use four 8T-4192 Bolts (13), and four 5P-1076 Hard Washers (14) .

Front Walk Way - Install

Table 65

Item	Part Number	Description
1	8T-4139	Bolt
2	5P-1076	Hard Washer
3	8T-0106	Bolt

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Illustration 328	g02457400

1. Install the front walkway assembly to the machine. Use two 8T-4139 Bolts (1), five 5P-1076 Hard Washers (2), and three 8T-0106 Bolts (3) .

   Note: Ensure that you use the correct three holes on the support. Refer to Illustration 328.

2. Repeat the above step for the right side of the walkway.

Walkway Group - Install

Illustration 329	g02458936

Table 66

370-6604 Walkway Gp
1	4	264-7377	Grate As
2	4	264-7378	Grate As
3	4	264-7392	Bracket As
4	4	264-7393	Bracket As
367-9499 Fastener Gp
5	16	8T-4139	Bolt
6	16	5P-1076	Hard Washer

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Illustration 330	g02459036
Right front side of bumper

1. Remove two bolts (A) and hard washer (B) from the front of the rear bumper. Repeat for the other side of the bumper.

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Illustration 331	g02459082

2. Install 264-7392 Bracket Assembly (3), and 264-7393 Bracket Assembly (4) to the rear frame Use four 8T-4139 Bolts (5), and four 5P-1076 6

3. Install 264-7378 Grate Assembly (10) to the bumper.

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Illustration 332	g02458958

4. Install 264-7378 Grate Assembly (2) to the bracket assemblies. Use four 8T-4139 Bolts (5), and four 5P-1076 Hard Washers (6) .

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Illustration 333	g02459096

5. Install bolt (A) and hard washer (B) to the grate assembly.

6. Tighten the bolts that were removed from the bumper to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 269.

7. Tighten eight 8T-4139 Bolts (2) bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

8. Repeat Step 2 through Step 7 for the other side of the machine. Substitute the following item.
   • 264-7377 Grate Assembly for 264-7378 Grate Assembly

Precleaners and Dust Ejectors - Install

Table 67

184-3214 Air Cleaner Gp
Item	Qty	Part Number	Description
1	4	187-4540	Air Cleaner Adapter
2	4	184-3200	Air Cleaner Group
3	40	9M-2151	Taperlock Stud
4	40	8T-4896	Hard Washer
5	16	8T-4184	Bolt
6	4	7M-1674	Filter Element
7	40	2K-4973	Locknut
8	4	1P-9390	Outlet Gasket
146-8053 Precleaner Group
9	4	145-9987	Adapter Assembly
10	4	130-3281	Precleaner
133-6613 Precleaner Group
11	4	7S-3687	Hood Assembly
12	4	7N-5973	Precleaner Body
133-6503 Filter Change Indicator Group
13	4	7W-7417	Service Indicator
14	4	5M-6214	Pipe Plug
15	4	5K-5068	Fitting
16	4	3B-6552	Elbow
129-0581 Dust Ejector Group
17	2	136-1612	Clip
18	2	133-5935	Dust Ejector
19	8	8T-6703	Hose Clamp
20	2	8T-4244	Nut
21	4	8T-4223	Hard Washer
22	2	8T-4139	Bolt
23	4	8T-4136	Bolt
24	4	8T-4121	Hard Washer
25	2	7E-1397	Pipe Clamp
26	4	5P-4325	Clip
27	4	5P-1471	Hose (1)
129-0580 Fumes Disposal Group
28	4	178-6366	Tube
29	2	178-6365	Elbow
30	2	175-5244	Fumes Disposal Group
31	2	136-1612	Clip
32	2	8T-4244	Nut
33	4	8T-4223	Hard Washer
34	2	8T-4139	Bolt
35	8	5P-4868	Hose Clamp
36	-	5P-1261	Hose
311-3616 Fumes Disposal Group
37	4	311-3620	Plate As
38	8	311-3615	Strap
39	4	311-3614	Strap
40	4	092-3206	Spacer
41	24	039-8557	Washer
42	4	8T-6466	Bolt
43	4	8T-4196	Bolt
44	12	8T-4195	Bolt
45	4	8T-4133	Nut

( 1 )

The hose should be cut into four equal lengths of 1320 mm (52 inch).

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Illustration 334	g01097115
Mounting Surface for Air Cleaner Assembly on Top of Hood (B) Shipping Cover

1. Remove four shipping plates (B) from the top of the hood. Remove shipping plates (B) in order to install the air cleaner groups. Refer to Illustration 334.

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Illustration 335	g01152819
Mounting Surface and O-Ring Seal for Air Cleaner Assembly

2. Inspect the mounting surface for the air cleaner assembly. Verify that the O-ring seal is properly installed into the groove. Refer to Illustration 335.

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Illustration 336	g00767051
Engine Compartment (C) Shipping cover

3. Remove four shipping covers (C) from the mufflers in the engine compartment. Remove shipping covers (C) in order to install the dust ejectors and the fumes disposal groups. Refer to Illustration 336.

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Illustration 337	g01152820
(1) Air Cleaner Adapter (3) Taperlock stud (8) Outlet gasket

Note: The following procedure is for one air cleaner assembly.

4. Apply 9S-3263 Thread Lock Compound onto 9M-2151 Taperlock Studs (3) before installation. Refer to Illustration 337.

5. Install ten 9M-2151 Taperlock Studs (3) into 187-4540 Air Cleaner Adapter (1). Refer to Illustration 337.

6. Tighten ten 9M-2151 Taperlock Studs (3) to a torque of 50 ± 10 N·m (35 ± 5 lb ft). Refer to Illustration 337.

7. Install 1P-9390 Outlet Gasket (8) onto 187-4540 Air Cleaner Adapter (1). Refer to Illustration 337.

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Illustration 338	g01152824
Cover (2) Air Cleaner Group

8. Remove the cover from 184-3200 Air Cleaner Group (2). Refer to Illustration 338.

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Illustration 339	g01152821
Primary Air Filter Element (2) Air Cleaner Group

9. Remove 6I-2509 Primary Air Filter Element from 184-3200 Air Cleaner Group (2) .

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Illustration 340	g01152822
Secondary Air Filter Element (2) Air Cleaner Group

10. Remove 6I-2510 Secondary Air Filter Element from 184-3200 Air Cleaner Group (2) .

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Illustration 341	g01152994
Exploded View of Air Cleaner Assembly (1) Air cleaner adapter (2) Air cleaner group (3) Taperlock stud (4) Hard washer (5) Bolt (6) Filter element (7) Locknut (8) Outlet gasket

Note: Verify that the outlet gasket is properly installed before the air cleaner group is mounted to the air cleaner adapter.

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Illustration 342	g01152823
Inside View of Air Cleaner Group (4) Hard washer (7) Locknut

11. Install 184-3200 Air Cleaner Group (2) onto 187-4540 Air Cleaner Adapter (1). Refer to Illustration 341.

12. Install 184-3200 Air Cleaner Group (2) with the following items: ten 8T-4896 Hard Washers (4) and ten 2K-4973 Locknuts (7). Refer to Illustration 341 and Illustration 342.

13. Tighten ten 2K-4973 Locknuts (7) to a torque of 50 ± 10 N·m (35 ± 5 lb ft). Refer to Illustration 342.

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Illustration 343	g01097490
Top View of Air Cleaner Assemblies

Note: Install the air cleaner assemblies at an angle toward the center of the hood.

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Illustration 344	g01152826
(1) Air cleaner adapter (5) Bolt

14. Install 187-4540 Air Cleaner Adapter (1) onto the mounting surface with four 8T-4184 Bolts (5). Refer to Illustration 344.

15. Tighten four 8T-4184 Bolts (5) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 344.

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Illustration 345	g01152822
Secondary Air Filter Element (2) Air Cleaner Group

16. Install 6I-2510 Secondary Air Filter Element into 184-3200 Air Cleaner Group (2). Refer to Illustration 345.

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Illustration 346	g01152821
Primary Air Filter Element (2) Air Cleaner Group

17. Install 6I-2509 Primary Air Filter Element into 184-3200 Air Cleaner Group (2). Refer to Illustration 346.

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Illustration 347	g01152824
Cover (2) Air Cleaner Group

18. Install the cover onto 184-3200 Air Cleaner Group (2). Refer to Illustration 347.

19. Repeat Step 4 through Step 18 for the other three air cleaner assemblies.

311-3616 Air Cleaner Mounting - Install

Note: The following procedure applies only to machines that are equipped with 133-6613 Precleaner Group .

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Illustration 348	g01789194

1. Install two 311-3615 Straps (38) onto the air cleaner group. Install 311-3615 Strap (38) onto the machine with 039-8557 Washer (41), 8T-4196 Bolt (43), and 8T-4133 Nut (45) .

2. Install 187-4540 Air Cleaner Adapter (1) onto the mounting surface with four 8T-4184 Bolts (5). Refer to Illustration 344.

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Illustration 349	g01789235

3. Place the 311-3614 Strap (39) onto 311-3615 Straps (38) .

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Illustration 350	g01789258

4. Secure 311-3620 Plate As (37) to the machine with 039-8557 Washer (41) and 8T-4195 Bolt (44) .

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Illustration 351	g01789295

5. Place the 311-3614 Strap (39) onto 311-3615 Straps (38) .

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Illustration 352	g01789313

6. Secure the 311-3614 Strap (39) on the left side of the air cleaner group with 8T-4195 Bolt (40) and 039-8557 Washer (41). Secure the 311-3614 Strap (39) on the right side of the air cleaner group with 092-3206 Spacer (40), 039-8557 Washer (41), and 8T-6466 Bolt (42) .

7. Repeat Step 1 through Step 6 for the other three air cleaner assemblies.

133-6613 Precleaner Group - Install

Note: The following procedure applies only to machines that are equipped with 133-6613 Precleaner Group .

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Illustration 353	g01152827
Precleaner Group (12) Precleaner body

1. Install 7N-5973 Precleaner Body (12) onto the air cleaner group. Refer to Illustration 353.

   Note: Position 7N-5973 Precleaner Body (12) so the outlet for the dust ejector hose faces toward the outside of the machine.

2. Tighten the clamp for the precleaner body. Refer to Illustration 353.

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Illustration 354	g01097489
Precleaner Group (11) Hood assembly (12) Precleaner body

3. Install 7S-3687 Hood Assembly (11) onto 7N-5973 Precleaner Body (12). Refer to Illustration 354.

4. Tighten the clamp for 7S-3687 Hood Assembly (11). Refer to Illustration 354.

146-8053 Precleaner Group - Install

Note: The following procedure applies only to machines that are equipped with 146-8053 Precleaner Group .

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Illustration 355	g01152827
Precleaner Group (12) Precleaner body

Note: Position 7N-5973 Precleaner Body (12) so the outlet for the dust ejector hose faces toward the outside of the machine.

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Illustration 356	g01152828
Precleaner Group (9) Adapter assembly (10) Precleaner

1. Install 145-9987 Adapter Assembly (9) onto 7N-5973 Precleaner Body (12). Refer to Illustration 355 and Illustration 356.

2. Tighten the clamp for 145-9987 Adapter Assembly (9). Refer to Illustration 356.

3. Install 130-3281 Precleaner (10) onto 145-9987 Adapter Assembly (9). Refer to Illustration 356.

4. Tighten the clamp for 130-3281 Precleaner (10). Refer to Illustration 356.

Filter Change Indicator Group - Install

Note: Install the service indicator into the side of the air cleaner adapter that is facing toward the exhaust stacks. The loose bolts will aid in the view of the service indicator.

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Illustration 357	g01152829
(1) Air cleaner adapter (6) Filter element (13) Service indicator (15) Fitting (16) Elbow

Note: The following procedure is for one filter change indicator group.

1. Install 7M-1674 Filter Element (6) into 187-4540 Air Cleaner Adapter (1). Refer to Illustration 341 and Illustration 357.

2. Apply 5P-3413 Pipe Sealant to 5K-5068 Fitting (15) before installation into 187-4540 Air Cleaner Adapter (1) .

3. Install 5K-5068 Fitting (15) into 187-4540 Air Cleaner Adapter (1). Refer to Illustration 357.

4. Install 3B-6552 Elbow (16) onto 5K-5068 Fitting (15). Refer to Illustration 357.

   Note: Position the elbow so that the elbow faces downward.

5. Install 7W-7417 Service Indicator (13) onto 3B-6552 Elbow (16). Refer to Illustration 357.

6. Apply 5P-3413 Pipe Sealant to 5M-6214 Pipe Plug (14) before installation into 187-4540 Air Cleaner Adapter (1) .

7. Install 5M-6214 Pipe Plug (14) into the other side of 187-4540 Air Cleaner Adapter (1) .

8. Repeat Step 1 through Step 7 for the other three filter change indicator groups.

Dust Ejector Group - Install

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Illustration 358	g01096980
Top View of Hood (A) Plate

1. Remove two plates (A) from the top of the hood. Refer to Illustration 358.

   Note: The removal of the two plates will aid in the installation of the dust ejectors and the fumes disposal group.

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Illustration 359	g01156123
Top View of Hood on Left Hand Side (18) Dust ejector (20) Fumes disposal group

Note: The 133-5935 Dust Ejector (18) is mounted on each of the front mufflers.

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Illustration 360	g01156118
Enlarged View of Dust Ejector (18) Dust ejector

Note: The following procedure is for one dust ejector group.

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Illustration 361	g01156046
Assembled View of Dust Ejector and Hose (18) Dust ejector (19) Hose clamp (23) Bolt (24) Hard washer (25) Bent bolt clamp (26) Clip (27) Hose

2. Install 133-5935 Dust Ejector (18) with 7E-1397 Bent Bolt Clamp (25). Refer to Illustration 361.

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Illustration 362	g01152830
Bottom View of Dust Ejector in Engine Compartment (18) Dust ejector (19) Hose clamp (27) Hose

3. Connect 5P-1471 Hose (27) to the 133-5935 Dust Ejector (18) with 8T-6703 Hose Clamp (19). Refer to Illustration 361 and Illustration 362.

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Illustration 363	g01156223
Mounting Plate for Precleaner (23) . (24) . (26) . (23) Bolt (24) Hard washer (26) Clip (27) Hose

4. Install 5P-1471 Hose (27) to the mounting plate for the precleaner. Refer to Illustration 363.

5. Install 5P-1471 Hose (27) with the following items: 8T-4136 Bolt (23), 8T-4121 Hard Washer (24) and 5P-4325 Clip (26). Refer to Illustration 363.

6. Tighten 8T-4136 Bolt (23) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 363.

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Illustration 364	g01156225
Precleaner Body (19) Hose clamp (27) Hose

7. Connect 5P-1471 Hose (27) to the precleaner body with 8T-6703 Hose Clamp (19). Refer to Illustration 364.

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Illustration 365	g01156048
Dust Ejector in Engine Compartment (17) Clip (20) Nut (21) Hard washer (22) Bolt

8. Install 136-1612 Clip (17) to the brace that supports the muffler group. Refer to Illustration 365.

9. Install 136-1612 Clip (17) with the following items: 8T-4244 Nut (20), 8T-4223 Hard Washer (21) and 8T-4139 Bolt (22). Refer to Illustration 365.

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Illustration 366	g01156232
Bottom View of Dust Ejector with Heat Shield in Engine Compartment

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Illustration 367	g01156233
Enlarged View of Heat Shield in Engine Compartment

10. Install the heat shield onto the dust ejector. Refer to Illustration 366.

11. Fasten the heat shield with the springs that are attached to the heat shield. Refer to Illustration 367.

12. Repeat Step 2 through Step 11 for the rear muffler on the other side of the machine.

Fumes Disposal Group - Install

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Illustration 368	g01156123
Top View of Hood on Left Hand Side (18) Dust ejector (30) Fumes disposal group

Note: The 175-5244 Fumes Disposal Group (30) is mounted on each of the rear mufflers.

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Illustration 369	g01156278
Enlarged View of Fumes Disposal Group (30) Fumes disposal group

Note: The following procedure is for one fumes disposal group.

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Illustration 370	g01156252
Upper View of Fumes Disposal Group in Engine Compartment (28) Tube (29) Elbow (30) Fumes disposal group (35) Hose clamp (36) Hose

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Illustration 371	g01156253
Enlarged View of Fumes Disposal Group in Engine Compartment (28) Tube (29) Elbow (30) Fumes disposal group (35) Hose clamp

1. Install 175-5244 Fumes Disposal Group (30) onto the muffler.

2. Connect 178-6365 Elbow (29) to 175-5244 Fumes Disposal Group (30) with 5P-4868 Hose Clamp (35). Refer to Illustration 370 and Illustration 371.

3. Install 178-6366 Tube (28) into 178-6365 Elbow (29) with 5P-4868 Hose Clamp (35). Refer to Illustration 370 and Illustration 371.

4. Connect 5P-1261 Hose (36) to 178-6366 Tube (28) with 5P-4868 Hose Clamp (35). Refer to Illustration 370 and Illustration 371.

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Illustration 372	g01156276
Tee for Fumes Disposal in Engine Compartment

5. Remove the shipping cover from the tee that is between the crankcase breathers. Retain the hose clamp for future use. Refer to Illustration 372.

6. Loosen the hose clamps that connect the tee to the crankcase breathers. Rotate the tee by 180 degrees.

7. Tighten the hose clamps that connect the tee to the crankcase breathers. The tee should face upward.

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Illustration 373	g01156255
Tee for Crankcase Breather in Engine Compartment (28) Tube (35) Hose clamp (36) Hose

8. Install 178-6366 Tube (28) into the tee. Install the hose clamp that was removed from the shipping cover for the tee. Refer to Illustration 373.

9. Connect 5P-1261 Hose (36) to 178-6366 Tube (28) with 5P-4868 Hose Clamp (35). Refer to Illustration 373.

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Illustration 374	g01156256
Assembled View of Hose for Fumes Disposal Group (19) Hose clamp (23) Bolt (24) Hard washer (26) Clip (36) Hose

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Illustration 375	g01156303
Bottom View of Fumes Disposal Group in Engine Compartment

10. Install 5P-1261 Hose (36) onto 175-5244 Fumes Disposal Group (30) with 8T-6703 Hose Clamp (19). Refer to Illustration 374 and Illustration 375.

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Illustration 376	g01156288
Mounting Plate for Precleaner (23) Bolt (24) Hard washer (26) Clip (36) Hose

11. Install 5P-1261 Hose (36) to the mounting plate for the precleaner. Refer to Illustration 376.

12. Install 5P-1261 Hose (36) with the following items: 8T-4136 Bolt (23), 8T-4121 Hard Washer (24) and 5P-4325 Clip (26). Refer to Illustration 376.

13. Tighten the bolt to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 376.

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Illustration 377	g01156291
Precleaner Body (19) Hose clamp (36) Hose

14. Connect 5P-1261 Hose (36) to the precleaner body with 8T-6703 Hose Clamp (19). Refer to Illustration 377.

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Illustration 378	g01156292
Fumes Disposal Group in Engine Compartment (31) Clip (32) Nut (33) Hard washer (34) Bolt

15. Install 136-1612 Clip (31) to the brace that supports the muffler group. Refer to Illustration 378.

16. Install 136-1612 Clip (31) with the following items: 8T-4244 Nut (32), 8T-4223 Hard Washer (33) and 8T-4139 Bolt (34). Refer to Illustration 378.

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Illustration 379	g01156232
Bottom View of Fumes Disposal Group with Heat Shield in Engine Compartment

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Illustration 380	g01156233
Enlarged View of Heat Shield in Engine Compartment

17. Install the heat shield onto the fumes disposal group. Refer to Illustration 379.

18. Fasten the heat shield with the springs that are attached to the heat shield. Refer to Illustration 380.

19. Repeat Step 1 through Step 18 for the front muffler on the other side of the machine.

20. Reinstall the two plates that were removed from the hood in Step 1 in section ""Install the Dust Ejector Group" " in this Special Instruction.

Exhaust Extensions - Install

Table 68

135-3879 Exhaust Extension
Item	Qty	Part Number	Description
1	4	147-5203	Exhaust Stack
2	8	280-0513	Clamp As
3	24	5P-1076	Hard Washer
4	8	5P-7468	Clip
5	8	5P-7469	Clip
6	8	6V-1874	Grommet
7	16	8T-4121	Hard Washer
8	8	8T-4133	Nut
9	16	8T-4139	Bolt
10	8	8T-4183	Bolt
11	8	8T-4195	Bolt
12	8	8T-4123	Plated Washer
13	8	8T-4244	Nut
Handrails for the Exhaust Extensions
14	1	369-4113	Handrail As
15	4	8T-4139	Bolt
16	4	8T-4121	Hard Washer
17	8	8T-4136	Bolt
18	1	365-0713	Handrail As

Note: The following procedure is for one exhaust extension.

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Illustration 381	g00767160
Installation of Exhaust Stacks (1) Exhaust stack (2) Bolt (3) Hard washer

1. Install 147-5203 Exhaust Stack (1) onto the plate that is located on top of the hood. Refer to Illustration 381.

2. Install 147-5203 Exhaust Stack (1) with the following items: four 8T-4139 Bolts (9) and four 5P-1076 Hard Washers (3). Refer to Illustration 381.

3. Tighten four 8T-4139 Bolts (2) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 381.

4. Repeat Step 1 and Step 3 for the other three exhaust extensions.

5. Install the hand rails for the exhaust extensions.

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Illustration 382	g01166275
Left Hand Side of Hood (1) Handrail

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Illustration 383	g01152621
Top of Hood and Mounting Blocks for Handrails

6. Install 369-4113 Handrail to the top and left-hand side of the hood. Refer to Illustration 382.

   Note: These Handrail assemblies provide protection around the exhaust extensions. The mounting blocks are welded onto the hood.

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Illustration 384	g02628676
Left Hand Side of Hood (14) Handrail (15) Bolt (16) Hard washer

7. Install 369-4113 Handrail (14) with the following items: four 8T-4139 Bolts (15) and four 8T-4121 Hard Washers (16) .

8. Tighten eight 8T-4136 Bolts (17) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

9. Repeat the above steps for the right-hand side of the machine. Substitute the following item.
   • 365-0713 Handrail for 369-4113 Handrail

10. Install the fasteners for the handrails that are installed around the exhaust extensions. Refer to Special Instruction, REHS4997, "994H Wheel Loader Assembly Procedure", "Handrails for the Hood - Install" for the fastener locations and procedures.

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Illustration 385	g01261417
Components for Exhaust Stack (1) Exhaust pipe (2) Clamp assembly (3) Hard washer (4) Clip (5) Clip (6) Grommet (7) Hard washer (8) Nut (9) Bolt (10) Bolt (11) Bolt (12) Washer (13) Nut

11. Install 230-0513 Clamp Assembly (2) onto the rear exhaust stack on the left-hand side of the machine. Refer to Illustration 385.

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Illustration 386	g01261507
Rear Exhaust Stack on Left Hand Side (2) Clamp assembly (8) Bolt (9) Hard washer

12. Assemble 280-0513 Clamp Assembly (2) with the following items: two 8T-4195 Bolts (8), two 8T-4121 Hard Washers (9) and Two 8T-4133 Nuts (13). Refer to Illustration 385.

    Note: Do not tighten the bolts at this time. This procedure will aid in the alignment and installation of the fasteners for the handrail.

13. Install two 280-0513 Clamp Assembly (2) onto the front exhaust stack on the left-hand side of the machine. Refer to Illustration 385.

14. Assemble two 280-0513 Clamp Assembly (2) with the following items: two 8T-4195 Bolts (11) and two 8T-4121 Hard Washers (7). Refer to Illustration 385.

    Note: Do not tighten the bolts at this time. This procedure will aid in the alignment and installation of the fasteners for the handrail.

15. Repeat Step 11 and Step 12 for the rear exhaust stack on the right-hand side of the machine.

16. Repeat Step 13 and Step 14 for the front exhaust stack on the right-hand side of the machine.

    Note: The following procedure is for one fastener for the hand rail.

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Illustration 387	g01261556
Clamp Assembly on Hand Rail for Exhaust Extension (2) Bolt (4) Clip (5) Clip (6) Grommet (9) Hard washer (10) Bolt

17. Install the following items to the hand rail: 6V-1874 Grommet (6), 5P-7468 Clip (4) and 5P-7469 Clip (5). Refer to Illustration 385 and Illustration 387.

18. Install 5P-7468 Clip (4) and 5P-7469 Clip (5) to the assembled clamps that are located on the exhaust stack. Refer to Illustration 385 and Illustration 387.

19. Install 5P-7468 Clip (4) and 5P-7469 Clip (5) with 8T-4139 Bolt (9). Refer to Illustration 385 and Illustration 387.

20. Tighten 8T-4139 Bolt (9) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 385 and Illustration 387.

21. Repeat Step 17 through Step 20 for the other seven handrail fasteners.

22. Tighten eight 8T-4183 Bolts (10) that hold the assembled clamps around the exhaust stack. Refer to Illustration 387.

23. Tighten eight 8T-4183 Bolts (10) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 387.

Front Fenders - Install

Table 69

354-6577 Fender Gp
1	1	347-8315	Fender As Left Hand Side
2	1	347-8316	Fender As Right Hand Side
3	2	314-3986	Film
319-0805 Flood Lighting Gp
4	6	204-2281	Cable Strap
5	6	204-8000	Cable Tie Mounting
6	2	266-9373	Support Assembly
7	2	266-9374	Guard As
8	2	319-0804	Lighting Harness As
9	8	330-5646	Mount
10	6	353-2834	Flood Lamp Gp
11	6	353-2835	Mounting Bracket As
12	2	130-5300	Clip
13	2	2D-1290	Grommet
14	2	7K-1659	Grommet
15	20	8T-4121	Hard Washer
16	16	8T-4133	Nut
17	16	8T-4183	Bolt
18	6	8T-4186	Bolt
19	4	8T-4195	Bolt
20	16	8T-4223	Hard Washer
21	2	9K-0700	Grommet
253-1580 Fender Fastener Group
22	8	5R-5927	Washer
23	8	8G-0841	Mount As
24	2	253-1581	Plate As
25	12	5P-1076	Hard Washer
26	10	7X-2563	Bolt
27	12	7X-2563	Bolt
28	8	8T-4648	Bolt
29	10	8T-5439	Plated Washer

Note: Do not install the front fenders at this time if the machine is the super high lift.

Note: The following procedure is for the front fender on the left-hand side of the machine.

1. Attach chains or cables to the front fender. Use a suitable lifting device in order to lift the front fender. The weight of the front fender is 245 kg (540 lb).

2. Lift the front fender to a level position. Support the front fender.

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Illustration 388	g03361601
Front Fender for Left Hand Side (4) 204-2281 Cable Strap (5) 204-8000 Cable Tie Mounting (6) 266-9373 Support As (12) 130-5300 Clip (14) 7K-1659 Grommet (15) 8T-4121 Hard Washer (17) 8T-4183 Bolt (18) 8T-4186 Bolt (19) 8T-4195 Bolt (20) 8T-4223 Hard Washer (21) 9K-0700 Grommet

Note: Install Grommet (14) for the wiring harness into Support As (6) before installing the support assembly to the fender.

3. Install 7K-1659 Grommet (14) into 266-9373 Support Assembly (6)

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Illustration 389	g03361703
Front Fender for Left Hand Side (1) 347-8315 Fender As (LH) (6) 266-9373 Support As (17) 8T-4183 Bolt (20) 8T-4223 Hard Washer

4. Install 266-9373 Support Assembly (6) to 347-8315 Fender As (1) for the left-hand side. Use eight 8T-4223 Hard Washers (20), and eight 8T-4183 Bolts (17) .

5. Tighten eight 8T-4183 Bolts (17) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 389.

6. Route the wiring harness through the support assembly and the front fender.

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Illustration 390	g03361715
(1) 347-8315 Fender As (LH) (5) 204-8000 Cable Tie Mounting (6) 266-9373 Support As (14) 7K-1659 Grommet (15) 8T-4121 Hard Washer (17) 8T-4183 Bolt (18) 8T-4186 Bolt (20) 8T-4223 Hard Washer (21) 9K-0700 Grommet

7. Install 9K-0700 Grommet (21) into 347-8315 Fender As (1) .

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Illustration 391	g03361736
(1) 347-8315 Fender As (LH) (4) 204-2281 Cable Strap (5) 204-8000 Cable Tie Mounting (8) 319-0804 Lighting Harness As (12) 130-5300 Clip (15) 8T-4121 Hard Washer (18) 8T-4186 Bolt (19) 8T-4195 Bolt

8. Assemble 204-8000 Cable Tie Mount (5) to fender (1). Use one 8T-4186 Bolts (18), and one 8T-4121 Hard Washers (15) .

9. Assemble 130-5300 Clip (12) to fender (1). Use one 8T-4195 Bolt (19), and one 8T-4121 Hard Washer (15) .

10. Tighten two 8T-4195 Bolts (19) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 390 and Illustration 391.

11. Secure the harness for the light to clip (12). Use a 204-2281 Cable Strap (4) .

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Illustration 392	g01157502

12. Attach chains or cables to the front fender. Use a suitable lifting device in order to lift the front fender. The weight of the front fender is 245 kg (540 lb).

13. Adjust the lifting device in order to lift the front fender evenly. Lift the front fender into position.

14. Install 347-8315 Left Hand Fender (1) onto the loader frame. Refer to Illustration 392.

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Illustration 393	g03361804
Front Fender for Left Hand Side (1) 347-8315 Fender As (LH) (22) 5R-5927 Washer (23) 8G-0841 Mount As (24) 253-1581 Plate As (25) 5P-1076 Hard Washer (26) 7X-2563 Bolt (27) 8T-4139 Bolt (28) 8T-4648 Bolt (29) 8T-5439 Hard Washer

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Illustration 394	g03361854
Enlarged View of Fasteners for Front Fender (26) 7X-2563 Bolts (29) 8T-5439 Plated Washers

15. Assemble 347-8315 Left Hand Fender (1) with the following items: five 8T-5439 Plated Washers (29) and five 7X-2563 Bolts (26). Refer to Illustration 393 and Illustration 394.

16. Assemble 347-8315 Left Hand Fender (1) to the drawbar. Use the following hardware:
    • one 253-1581 Plate As (24)

    • four 8G-0841 Mount As (23)

    • four 8T-4648 Bolts (28)

    • six 8T-4139 Bolts (27)

    • six 5P-1076 Hard Washers (24)

17. Tighten five 7X-2563 Bolts (26) to a torque of 460 ± 60 N·m (340 ± 45 lb ft). Refer to Illustration 393 and Illustration 394.

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Illustration 395	g02459376

18. Connect the wiring harness from the machine to the wiring harness for the floodlights on the front fender.

19. Secure the wiring harness to the front fender. Use a 204-2281 Cable Strap (4) .

20. Repeat Step 2 through Step 18 for the front fender on the right-hand side of the machine. Substitute the following item.
    • 347-8315 Fender As (LH) (1) for 347-8316 Fender As (RH) (2) .

Machine Lighting - Install

Brake Light - Install

Table 70

351-7158 Stop Lighting Gp
Item	Qty	Part Number	Description
1	2	116-0118	Clip
2	4	230-8152	Spacer
3	1	219-0602	Bracket Assembly Right Hand Side
4	1	219-0601	Bracket Assembly Left Hand Side
5	2	334-8049	Signal Lamp Gp
6	4	8T-6411	Screw
7	2	8T-4205	Washer
8	8	8T-4195	Bolt
9	8	8T-4121	Hard Washer
10	2	8P-8540	Grommet
11	6	5C-2890	Nut
12	1	4E-9925	Cover Left Hand Side
13	1	4E-9924	Cover Right Hand Side

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Illustration 396	g01156647
Right Hand Side of Radiator Guard (3) Bracket assembly (8) Bolt (9) Hard washer

Note: The following procedure is for the brake light on the right-hand side of the machine.

1. Install 219-0602 Bracket Assembly (3) onto the right-hand side of the radiator guard. Use four 8T-4195 Bolts (8), and four 8T-4121 Hard Washers (9) .

2. Tighten four 8T-4195 Bolts (8) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 396.

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Illustration 397	g01156717
Right Hand Side of Rear Frame at Rear of Machine (3) Bracket assembly (10) Grommet

3. Route the wiring harness through the rear hole of 219-0602 Bracket Assembly (3). Refer to Illustration 397.

4. Install 8P-8540 Grommet (10) into 219-0602 Bracket Assembly (3) .

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Illustration 398	g01156660
Fasteners for Signal Lamp (5) Signal lamp (11) Nut

5. Install 334-8049 Signal Lamp Gp (5) to the bracket assembly. Refer to Illustration 398.

6. Install 334-8049 Signal Lamp Gp (5) with two 5C-2890 Nuts (11). Refer to Illustration 398.

7. Tighten two 5C-2890 Nuts (11) to a torque of 12 ± 3 N·m (8 ± 2 lb ft). Refer to Illustration 398.

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Illustration 399	g01156673
Enlarged View of Fasteners for Signal Lamp (1) Clip assembly (2) Spacer (7) Washer (11) Nut

8. Install 116-0118 Clip As (1) to the bracket assembly. Use one 8T-4205 Hard Washer (7), and one 5C-2890 Nut (11). Refer to Illustration 399.

   Note: The clip assembly is mounted to the inner stud and the top stud for the signal lamp.

9. Tighten 5C-2890 Nut (11) to a torque of 12 ± 3 N·m (8 ± 2 lb ft). Refer to Illustration 399.

10. Connect the wiring harness from the machine to the signal lamp. Install the wiring harness connector onto 116-0118 Clip (1). Refer to Illustration 399.

11. Install two 230-8152 Spacers (2) onto two of the studs. Refer to Illustration 399.

    Note: One of the studs will be located at the lower portion and the middle portion of the bracket assembly. The other stud will be located at the upper portion and the outer portion of the bracket assembly.

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Illustration 400	g01156718
Cover for Signal Lamp on Left Hand Side of Radiator Guard (5) Signal lamp (6) Screw

12. Install 4E-9924 Cover (13) to the two spacers on the bracket assembly.

13. Install 4E-9924 Cover (13) with two 8T-6411 Screws (6). Refer to Illustration 400.

14. Repeat Step 1 through Step 13 for the signal lamp on the left-hand side of the machine. Substitute the following items.
    • 219-0601 Bracket Assembly for 219-0602 Bracket Assembly

    • 4E-9925 Cover for 4E-9924 Cover

Rear Lighting - Install

Table 71

351-7155 Lighting Gp
Item	Qty	Part Number	Description
1	2	347-9427	Flood Lamp Gp
2	4	8T-4137	Bolt
3	4	8T-4121	Hard Washer
4	2	6V-9189	Locknut
351-7170 Rear Wiring Gp
5	2	8T-4136	Bolt
6	2	8T-4121	Hard Washer
7	2	204-8000	Cable Tie Mounting
8	2	204-2281	Cable Strap

Illustration 401	g02460477

1. Install 347-9427 Flood Lamp Gp (1) onto the bracket. Use a 8T-4137 Bolt (2), 8T-4121 Hard Washer (3), and a 6V-9189 Locknut (4)

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Illustration 402	g02460517

2. Install 204-8000 Cable Tie Mount (7). Use a 8T-4136 Bolt (5), and 8T-4121 Hard Washer (6) .

3. Connect the wiring harness from the machine to the receptacle on the HID light. The receptacle is located at the rear of the HID light.

   Note: Allow slack in the wiring harness in order to connect the wiring harness.

4. Secure the wiring harness from the light to the cable tie mount. Use a 204-2281 Cable Strap (8) .

5. Tighten two 8T-4136 Bolts (2) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

6. Repeat the steps above for the flood light on the other side of the machine.

Lighting Groups for the ROPS - Install

Table 72

319-0799 ROPS Lighting Gp
Item	Qty	Part Number	Description
1	4	353-2833	Flood Lamp Gp
2	4	353-2834	Flood Lamp Gp
3	4	353-2835	Mounting Bracket As
4	8	9X-9365	Bracket
5	4	8T-4136	Bolt
6	8	099-5307	Grommet
7	16	7X-7729	Hard Washer
8		8T-6912	Bolt
9	16	8T-4224	Hard Washer
10	8	131-3540	Locknut
11	4	8T-4135	Bolt
12	8	8T-4121	Hard Washer
13	4	8T-4133	Nut
14	4	9X-9365	Bracket
15	4	8T-4195	Bolt

Note: Install the lighting groups onto the ROPS before the ROPS is installed onto the machine.

1. Remove the shipping cover from the wiring harness on the front of the ROPS.

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Illustration 403	g02460636
Top view of the flood lamp for front of ROPS (1) 353-2833 Flood Lamp Gp (3) 353-2835 Mounting Bracket As (5) 8T-4136 Bolt (6) 099-5307 Grommet (7) 7X-7729 Washer (8) 8T-6912 Bolt (9) 8T-4224 Hard Washer (10) 131-3540 Locknut

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Illustration 404	g02460804

2. Install 353-2835 Mounting Bracket Assemblies (3) onto the front of the ROPS in four places. Use four 8T-4136 Bolts (5), 099-5307 Grommets (6), and eight 7X-7729 Hard Washers (7) .

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Illustration 405	g02460834

3. Install four 353-2833 Flood Lamp Groups (1) to the mounting brackets (3). Use four 8T-6912 Bolts (8), four 8T-4224 Hard Washers (9), and four 131-3540 Locknuts (10) .

4. Hand tighten 8T-6912 Bolt (8) .

   Note: Tighten the bolt after the flood lamp is adjusted for the view of the operator.

5. Connect the harness to the back of the flood lights.

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Illustration 406	g02460879

6. Remove two bolts (A) two hard washers (B), and two cable tie mounts (C) from the back of the ROPS. Retain the hardware.

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Illustration 407	g02460878

7. Install two 9X-9365 Brackets (14). Use the hardware from the previous step.

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Illustration 408	g02460881

8. Install two 353-2835 Mounting Bracket Assemblies (3). Use two 8T-4195 Bolts (15), four 7X-7729 Hard Washers (7), two 099-5307 Grommets (6), two 8T-4121 Hard Washers (12), and two 8T-4133 Nuts (13) .

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Illustration 409	g02460882

9. Install two 353-2834 Flood Lamp Groups (2), Use two 8T-6912 Bolts (8), two 8T-4224 Hard Washers (9), and two 131-3540 Locknuts (10) .

10. Hand tighten 8T-6912 Bolt (8)

    Note: Tighten the bolt after the flood lamp is adjusted for the view of the operator.

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Illustration 410	g02460883

11. Connect the harness to the back of the flood lights.

Front Light on ROPS - Install

Table 73

351-7155 Lighting Gp
Item	Qty	Part Number	Description
1	2	332-9402	Flood Lamp Gp
2	2	347-9427	Flood Lamp Gp
3	4	373-1524	Bracket
4	4	8T-4139	Bolts
5	4	8T-4223	Hard Washers
6	4	9X-6772	Cable Strap

Illustration 411	g02462319
Location of the front lights on the ROPS.

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Illustration 412	g02462337

1. Install two 373-1524 Brackets (3) onto the ROPS. Use two 8T-4139 Bolts (4), and two 8T-4223 Hard Washers (5) .

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Illustration 413	g02462338

2. Install 347-9427 Flood Lamp Gp (2) to the top bracket. Use bolt (A), hard washer (B), and nut (C) from lamp (2)

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Illustration 414	g02462340

3. Install 332-9402 Flood Lamp Gp (1) to the bottom bracket. Use bolt (D), hard washer (E), and nut (F) from lamp (1) .

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Illustration 415	g02462342

4. Connect the harness from the ROPS to the back of lamp (1) and lamp (2). Secure the harness to the ROPS. Use two 9X-6772 Cable Straps (6) .

Warning Beacon Lamp Gp - Install

Table 74

337-3371 Warning Beacon Lighting Ar
Item	Qty	Part Number	Description
1	2	351-7169	Bracket Assembly
2	2	338-1132	Warning Beacon Lamp Gp
3	2	130-5300	Clip
5	8	8T-4137	Bolt
5	8	8T-4121	Hard Washer
6	2	5P-9085	Clip

1. Remove the existing hardware from the warning beacon in order to install the warning beacon onto the bracket assembly.

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Illustration 416	g01159587
Bracket Assembly and Mounting Holes for Warning Beacon (1) Bracket assembly.

2. Install 338-1132 Warning Beacon Lamp Gp onto 351-7169 Bracket Assembly (1) .

3. Tighten the three bolts and nuts for the warning beacon to a torque of 12 ± 3 N·m (105 ± 25 lb in).

   Note: DO NOT overtighten the bolts and nuts for the warning beacon. The torque is listed in newton meters and inch pounds.

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Illustration 417	g01159588
Warning Beacon Lamp Group on the ROPS (1) Bracket assembly. (2) Lamp group. (4) Bolt. (5) Hard washer.

4. Install the warning beacon lamp group to the bracket that is located on the top and rear of the ROPS.

5. Install the warning beacon lamp group with the following items: two 8T-4137 Bolts (4) and two 8T-4121 Hard Washers (5) .

6. Tighten two 8T-4137 Bolts (4) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

Note: Install the clips onto the wiring harnesses with the flat side of the clip toward the mounting surface.

7. Install 130-5300 Clip (3) onto the wiring harness for the warning beacon.

8. Install 130-5300 Clip (3) to the boss that is located on the bottom of 351-7169 Bracket As (1) .

9. Install 130-5300 Clip (3) with the following items: 8T-4137 Bolt (4) and 8T-4121 Hard Washer (5) .

10. Tighten 8T-4137 Bolt (4) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

Flood Lighting Gp for the Platform - Install

Table 75

351-7149 Flood Lighting Gp
Item	Qty	Part Number	Description
1	2	353-2834	Flood Lamp Gp
2	2	353-2835	Mounting Bracket As
3	2	101-8418	Bracket
4	2	8T-4195	Bolt
5	4	8T-4224	Hard Washer
6	6	8T-4136	Bolt
7	6	8T-4121	Hard Washer
8	2	6V-9189	Locknut

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Illustration 418	g01143220
Assembled View of Flood Lamp on Right Hand Side of Platform (1) Flood lamp (2) Bracket (3) Bracket (4) Bolt (5) Hard washer (6) Bolt (7) Hard washer (8) Locknut

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Illustration 419	g01143221
Left Hand Side of Platform (1) Flood lamp (3) Bracket (6) Bolt (7) Hard washer

1. Route the wiring harness for the flood lamp from the platform to the location of the lamp.

2. Install 101-8418 Bracket (3) to the platform. Refer to Illustration 418 and Illustration 419.

3. Install 101-8418 Bracket (3) with the following items: two 8T-4136 Bolts (6) and two 8T-4121 Hard Washers (7). Refer to Illustration 418 and Illustration 419.

4. Install 130-6469 Bracket (2) to 153-2073 Flood Lamp (1). Refer to Illustration 418 and Illustration 419.

5. Install 130-6469 Bracket (2) with the following items: 8T-6869 Bolt (4), two 8T-4224 Hard Washers (5) and 6V-9189 Locknut (8). Refer to Illustration 418 and Illustration 419.

6. Install 153-2073 Flood Lamp (1) to 101-8418 Bracket (3) .

7. Install 153-2073 Flood Lamp (1) with the following items: 8T-4136 Bolt (6) and 8T-4121 Hard Washer (7). Refer to Illustration 418 and Illustration 419.

8. Tighten three 8T-4136 Bolts (6) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 418 and Illustration 419.

9. Tighten 6V-9189 Locknut (8) to a torque of 25 ± 5 N·m (18 ± 5 lb ft). Refer to Illustration 418 and Illustration 419.

10. Connect the electrical components to the back of 153-2073 Flood Lamp (1) .

11. Repeat Step 1 through Step 10 for the side light on the other side of the machine.

LED Flood Lighting Ar - Install (if equipped)

Table 76

416-9850 Flood Lighting Ar
Item	Qty	Part Number	Description
1	1	348-4856	Light Switch
2	1	351-7158	Stop Lighting Gp
3	1	416-9841	Flood Lighting Gp
4	1	416-9842	Flood Lighting Gp
5	1	416-9843	ROPS Lighting Gp
6	1	416-9844	Flood Lighting Gp
7	1	416-9845	Flood Lighting Gp
8	1	416-9846	ROPS Lighting Gp

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Illustration 420	g03380301
Right-hand console (1) Light Switch

1. Assemble 348-4856 Light Switch (1) to the Right-hand console in the operator station.

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Illustration 421	g03380340
Left rear of the machine (2) 351-7158 Stop Lighting Gp

2. Assemble 351-7158 Stop Lighting Gp (2) to the Left side of the radiator housing, facing the rear of the machine. Repeat this procedure for the right side of the machine.

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Illustration 422	g03382576
Left rear of the machine (2) 351-7158 Stop Lighting Gp (5) 416-9843 ROPS Lighting Gp

3. Assemble the rear lights for 416-9843 ROPS Lighting Gp (5) to 351-7158 Stop Lighting Gp (2) to the Left side of the radiator housing, facing the rear of the machine. Repeat this procedure for the right side of the machine.

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Illustration 423	g03382596
View of the top left of the cab (5) 416-9843 ROPS Lighting Gp

4. Assemble two front lights for 416-9843 ROPS Lighting Gp (5) to upper left side of the cab. Repeat this process for the right side of the cab.

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Illustration 424	g03382610
View of the left rear of the machine with door removed for clarity (4) 416-9842 Flood Lighting Gp

5. Assemble one light for the 416-9842 Flood Lighting Gp (4) inside the rear of the engine compartment. Repeat this process for the right side of the cab.

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Illustration 425	g03382625
View of the top, front area between the lift arms. Cover is removed for clarity (4) 416-9841 Flood Lighting Gp

6. Assemble the 416-9841 Flood Lighting Gp (4) between the lift arms at the front of the machine.

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Illustration 426	g03382714
(6) 416-9844 Flood Lighting Gp

7. Assemble the 416-9844 Flood Lighting Gp (6) to the front fenders facing forward.

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Illustration 427	g03382723
(7) 416-9845 Flood Lighting Gp

8. Assemble 416-9845 Flood Lighting Gp (7) to the left side of the machine on the front of the walkway. Repeat on the right side of the machine.

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Illustration 428	g03382739
Front view of the ROPS (8) 416-9846 ROPS Lighting Gp

9. Assemble lights for the 416-9846 ROPS Lighting Gp (8) to the front of the ROPS.

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Illustration 429	g03382748
Rear view of the ROPS (8) 416-9846 ROPS Lighting Gp

10. Assemble lights for the 416-9846 ROPS Lighting Gp (8) to the rear of the ROPS.

Steering Cylinders - Clean

Illustration 430	g00767634
Steering Cylinder with Shipping Grease on Left Hand Side of Machine (A) Steering cylinder rod

Remove the shipping grease from the steering cylinder rods (A) on both sides of the machine. Perform this procedure before the machine is turned.

Illustration 431	g00767635
Steering Cylinder without Shipping Grease on Left Hand Side of Machine (A) Steering cylinder rod

Lift Arms - Install

Table 77

Item	Qty	Part Number	Description
−	−	7M-7456	Sealant
−	−	5P-0960	Molybdenum Grease
5	3	4C-9431	Forcing Bolt
−	−	4C-5599	Anti-Seize Compound
1	1	245-1550 (1)	Lift Arm Assembly
245-1565 Linkage Pin and Seal
2	−	247-4129	Shim
3	−	247-4128	Shim
4	4	9X-7703	Lip Seal

( 1 )

The part number for the lift arm assembly will depend on the type of lift arms that are installed.

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Illustration 432	g02386537
Cutaway View of Lift Arm (A) Bolt (B) Washer (C) Nut (1) Lift arm assembly (2) Shim (3) Shim (4) Lip seal

1. Remove the following items from the lift arm pivot: 3E-8011 Bolt (A), two 9X-8399 Washers (B) and 8T-1583 Nut (C). Refer to Illustration 432.

   Note: The parts that were removed will be required during the installation procedure.

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Illustration 433	g00768195
(D) Lifting bracket

2. Attach chains or cables to lift bracket (D). Refer to Illustration 433.

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Illustration 434	g01882793
Forcing Bolts for Removal of Collet

3. Use forcing bolts in order to remove 245-3251 Collet (E). Refer to Illustration 434.

   Note: Use a hammer on the other end of the lift arm pivot in order to force the collet out of the pin bore.

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Illustration 435	g01172733
Lifting Device for Pin (F) Pin

4. Use a lifting device in order to remove 245-1558 Pin (F). Refer to Illustration 435.

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Illustration 436	g01172730
(D) Lifting bracket

5. Remove lifting bracket (D). Refer to Illustration 436.

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Illustration 437	g00768574
Removal of Inner Collet Assembly (G) Hose assembly

6. Disconnect 8X-1351 Hose Assembly (G) in order to remove the inside 245-3251 Collet that is on the right-hand side of the machine. Refer to Illustration 437.

   Note: Use a bar in order to force the other 245-3251 Collet out of the bore. Do not damage the inside of the collet during the removal process.

7. Repeat Step 1 through Step 6 for the lift arm pivot on the other side of the frame.

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Illustration 438	g01172904
(4) Lip seal

8. Apply 7M-7456 Sealant to the outside diameter of 9X-7703 Lip Seal (4) before installation. Refer to Illustration 438.

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Illustration 439	g01172905
(1) Lift arm assembly (4) Lip seal

9. Install two 9X-7703 Lip Seals (4) into the pin bores of 245-1550 Lift Arm Assembly (1). Refer to Illustration 439.

10. Verify that 9X-7703 Lip Seal (4) is seated evenly into the bore of 245-1550 Lift Arm Assembly (1). Refer to Illustration 439.

11. Repeat Step 8 through Step 10for the other side of the lift arm assembly.

12. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

13. Check the lift arm assembly and the loader frame.

14. Clean four 245-3251 Collets (E) and two 245-1558 Pins (F) .

15. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

16. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

17. Attach chains or cables to the lift arm assembly.

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Illustration 440	g01172902
Left Hand Side of Lift Arm Assembly (1) Lift arm assembly

18. Use a suitable lifting device in order to lift 245-1550 Lift Arm Assembly (1). The weight of the lift arm assembly is 23380 kg (51550 lb).

19. Use a heavy rope in order to control 245-1550 Lift Arm Assembly (1) from excessive movement during the installation procedure. Refer to Illustration 440.

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Illustration 441	g01172734
Lift Arm Assembly and Loader Frame (1) Lift arm assembly

20. Position 245-1550 Lift Arm Assembly (1) into the loader frame. Refer to Illustration 441.

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Illustration 442	g01172736
Side View of Lift Arm Assembly and Loader Frame (H) Gap (2) Shim (3) Shim

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Illustration 443	g01173046
Top View of Lift Arm Assembly and Loader Frame (H) Gap (2) Shim (3) Shim

Note: Gap (H) between the lift arm assembly and the loader frame should be equal on both sides of the lift arms.

21. Insert 247-4129 Shim (2) or 247-4128 Shim (3) into gap (H) on both sides of the lift arm assembly. Refer to Illustration 442 and Illustration 443.

22. Insert the same size of shims and the same number of shims on both sides of the lift arm assembly. The shims will equalize gap (H). Refer to Illustration 442 and Illustration 443.

    Note: Do not force the shims into gap (H) .

23. Record the number of shims and the size of shims that are installed into gap (H). Refer to Illustration 442 and Illustration 443.

24. Repeat Step 21 and Step 23 for the lift arm pivot on the other side of the loader frame.

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Illustration 444	g01172733
Lifting Device for Pin (F) Pin

25. Use a lifting device in order to install 245-1558 Pin (F). The weight of the pin is 165 kg (365 lb). Refer to Illustration 435.

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Illustration 445	g01174236
Typical View of Linkage Pin in Pin Bore

26. Measure the distance between the end of the pin and the loader frame. Refer to Illustration 445.

27. Position the pin in the pin bore so that there is an equal space on each end of the pin. Refer to Illustration 445.

Note: Apply 4C-5599 Anti-Seize Compound to the inside diameter of the collets.

28. Install two 245-3251 Collets (E) to each pin. Refer to Illustration 432.

    Note: The collets on each end of the pin should extend the same distance from the loader frame.

Note: Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

29. Install the following items to the lift arm pivot: 3E-8011 Bolt (A), two 9X-8399 Washers (B) and 8T-1583 Nut (C). Refer to Illustration 432.

30. Tighten 3E-8011 Bolt (A) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft). Refer to Illustration 432.

    Note: After the bolt is tightened, each collet should extend the same distance from the loader frame.

31. Strike the collets and the lift arm pivot with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

32. Tighten 3E-8011 Bolt (A) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft). Refer to Illustration 432.

33. Strike the collets and the lift arm pivot with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

34. Tighten 3E-8011 Bolt (A) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft). Refer to Illustration 432.

    Note: Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

35. Repeat Step 25 through Step 34 for the lift arm pivot on the other side of the machine.

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Illustration 446	g01172737
Jack Stands for Lift Arm Assembly (1) Lift arm assembly

36. Lower 245-1550 Lift Arm Assembly (1) onto two suitable jack stands. Refer to Illustration 446.

37. Remove all of the lifting devices from the lift arms.

38. Carefully fill the pin joint with the recommended lubricant.

39. Pin joints that are equipped with lip seals will be manually filled with grease.

40. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

41. Do not rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

Lift Cylinders - Connect

Table 78

Item	Qty	Part Number	Description
−	−	7M-7456	Sealant
−	−	5P-0960	Molybdenum Grease
−	−	4C-5599	Anti-Seize Compound
245-1565 Linkage Pin and Seal
1	2	156-5917	Collet
2	2	156-5916	Collet
3	2	9X-8399	Washer
4	2	8X-0662	Pin
5	4	7X-4786	Lip Seal
6	2	3E-8009	Bolt

Note: The grease port on the rod end of the lift cylinder should be oriented toward the front of the machine.

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Illustration 447	g00768210
Lifting Device for Lift Arms (A) Lift arms

1. Attach cables or chains to lift arms (A) .

2. Use a suitable lifting device in order to raise lift arms (A). Refer to Illustration 447.

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Illustration 448	g01173104
Lift Cylinder for Right Hand Side of Loader Frame

3. Raise the lift arms until the lift cylinder pin bore is clear of the frame. Refer to Illustration 448.

4. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

5. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

6. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

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Illustration 449	g01173116
(5) Lip seal

7. Apply 7M-7456 Sealant to the outside diameter of 7X-4786 Lip Seal (5) before installation. Refer to Illustration 449.

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Illustration 450	g01173110
Rod Eye End of Lift Cylinder on Left Hand Side of Loader Frame (5) Lip seal

8. Install two 7X-4786 Lip Seals (5) into the pin bores on the rod eye end of the lift cylinder. Refer to Illustration 450.

9. Verify that 7X-4786 Lip Seal (5) is seated evenly into the bore of the rod eye end on the lift cylinder. Refer to Illustration 450.

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Illustration 451	g01173107
Lift Cylinder on Right Hand Side of Loader Frame

10. Extend the lift cylinder until the rod eye end is aligned with the pin bore on the lift arm. Install 8X-0662 Pin (1). Refer to Illustration 451.

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Illustration 452	g01173318
Lifting Device for Pin (4) Pin

11. Use a lifting device in order to install 8X-0662 Pin (4). The weight of the pin is 95 kg (210 lb). Refer to Illustration 452.

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Illustration 453	g01173317
Rod Eye End of Lift Cylinder on Right Hand Side of Loader Frame (4) Pin

12. Install 8X-0662 Pin (4) into the pin bore of lift arm and the rod eye end of lift cylinder. Refer to Illustration 453.

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Illustration 454	g01174236
Typical View of Linkage Pin in Pin Bore

13. Measure the distance between the end of the pin and the lift arm. Refer to Illustration 454.

14. Position the pin in the pin bore so that there is an equal space on each end of the pin. Refer to Illustration 454.

15. Apply 4C-5599 Anti-Seize Compound to the inside diameter of the collets.

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Illustration 455	g02386517
Cutaway View of Rod End on Lift Cylinder (1) Collet (2) Collet (3) Washer (6) Bolt

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Illustration 456	g01737795
Inner Collet and Outer Collet for Rod Eye End on Lift Cylinder (1) Outside collet (2) Inside collet

Note: The outside collet has a larger hole in the middle for the mounting bolt. The inside collet has a smaller threaded hole for the mounting bolt.

16. Install 156-5917 Collet (1) into the pin bore on the outside of the lift arm. Refer to Illustration 455.

17. Install 156-5916 Collet (2) into the pin bore on the inside of the lift arm. Refer to Illustration 455.

    Note: The collets on each end of the pin should extend the same distance from the lift arm.

18. Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

19. Install 3E-8009 Bolt (6) with 9X-8399 Washer (3). The bolt threads should engage the threads on the inside of the 156-5917 Collet (1). Refer to Illustration 455.

    Note: Start the bolt from the outside collet on the lift arm.

20. Tighten 3E-8009 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: After the bolt is tightened, each collet should extend the same distance from the lift arm.

21. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

22. Tighten 3E-8009 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

23. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

24. Tighten 3E-8009 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

25. Repeat Step 10 through Step 24 for the lift cylinder on the other side of the machine.

26. Carefully fill the pin joint with the recommended lubricant.

27. Pin joints that are equipped with lip seals will be manually filled with grease.

28. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

29. Do not rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

30. Grease the rod end of the lift cylinder manually.

31. Lower the lift arms to the ground.

Tilt Cylinders - Install

Table 79

Item	Qty	Part Number	Description
−	−	7M-7456	Sealant
−	−	5P-0960	Molybdenum Grease
−	−	4C-5599	Anti-Seize Compound
245-1565 Linkage Pin and Seal
1	8	9X-8399	Washer
2	4	8T-1583	Nut
7	2	358-7033	Inside Collet
3	6	8R-3931	Collet
4	8	5P-2322	Lip Seal
5	4	3E-8009	Bolt
6	4	1V-8031	Pin

Note: Install the head end of the tilt cylinder into the loader frame. Perform this procedure before installing the rod eye end of the tilt cylinder.

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Illustration 457	g01173598
Pin Bores for Tilt Cylinders on Loader Frame

1. Clean the pin bores for the tilt cylinders on the loader frame. Refer to Illustration 457.

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Illustration 458	g01173602
(4) Lip seal

2. Apply 7M-7456 Sealant to the outside diameter of 5P-2322 Lip Seal (4) before installation. Refer to Illustration 458.

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Illustration 459	g01173604
Rod Eye End of Tilt Cylinder (4) Lip seal

3. Install two 5P-2322 Lip Seals (4) into the pin bores on the rod eye end of the tilt cylinder. Refer to Illustration 459.

4. Verify that 5P-2322 Lip Seal (4) is seated evenly into the pin bore on the rod eye of the tilt cylinder. Refer to Illustration 459.

5. Repeat Step 2 through Step 4 for the head end of the tilt cylinder.

6. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

7. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

8. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

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Illustration 460	g01173599
(A) Tilt cylinder

Note: The tilt cylinder hoses are installed on the tilt cylinders from the factory.

9. Use a suitable lifting device in order to lift the tilt cylinder. The weight of the tilt cylinder is 990 kg (2185 lb). Refer to Illustration 460.

Note: The grease port on the head end of the tilt cylinder should be oriented upward.

Note: The grease port on the rod eye end of the tilt cylinder should be oriented downward.

10. Verify that the head end and the rod eye end are aligned with each other.

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Illustration 461	g01173802
Top View of Tilt Cylinders on Loader Frame (A) Tilt cylinder

11. Install the tilt cylinders with the hoses toward the center of the loader frame. Refer to Illustration 461.

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Illustration 462	g01173601
Top View of Loader Frame (A) Tilt cylinder

12. Align the pin bore in the head end of the tilt cylinder (A) with the pin bore on the loader frame. Refer to Illustration 462.

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Illustration 463	g01173607
Lifting Device for Pin (6) Pin

13. Use a lifting device in order to lift 1V-8031 Pin (6). The weight of the pin is 55 kg (120 lb). Refer to Illustration 463.

14. Install 1V-8031 Pin (6) into the pin bore.

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Illustration 464	g01174236
Typical View of Linkage Pin in Pin Bore

15. Measure the distance between the end of the pin and the loader frame. Refer to Illustration 464.

16. Position the pin in the bore so that there is an equal space on each end of the pin. Refer to Illustration 464.

17. Apply 4C-5599 Anti-Seize Compound to the inside diameter of the collets.

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Illustration 465	g02378016
Cutaway View of Pin for Tilt Cylinder (1) Washer (2) Nut (3) 8R-3931 Collet (4) Lip seal (5) Bolt (6) Pin (7) 358-7033 Collet

18. Install one 8R-3931 Outside Collet (3) and one 358-7033 inside Collet (7) into the pin bores on the loader frame. Refer to Illustration 465.

    Note: The collets on each end of the pin should extend the same distance from the loader frame.

19. Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

20. Install 9X-8399 Washer (1) and 3E-8009 Bolt (5) through 8R-3931 Outside Collet (3) and 358-7033 Inside . Refer to Illustration 465.

    Note: Start the bolt from the inside collet on the tilt cylinder.

21. Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

22. Install 8T-1583 Nut (2) and 9X-8399 Washer (4) onto 3E-8009 Bolt (5). Refer to Illustration 465.

23. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: After the bolt is tightened, each collet should extend the same distance from the loader frame.

24. Strike the collets and the head end of the tilt cylinder with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

25. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

26. Strike the collets and the head end of the tilt cylinder with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

27. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

28. Carefully fill the pin joint with the recommended lubricant.

29. Pin joints that are equipped with lip seals will be manually filled with grease.

30. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

31. DO NOT rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

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Illustration 466	g00768463
Positioning of Tilt Lever (B) Come-along

32. Use a come-along (B) in order to position the tilt lever so that the rod eye end of the tilt cylinder can be installed. Refer to Illustration 466.

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Illustration 467	g01173806

33. Attach chains or cables to the tilt cylinder.

34. Align the pin bore on the rod eye end of the tilt cylinder and the pin bore on the tilt lever. Refer to Illustration 467.

35. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

36. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

37. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

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Illustration 468	g01173607
Lifting Device for Pin (6) Pin

38. Use a suitable lifting device in order to lift 1V-8031 Pin (6). The weight of the pin is 55 kg (120 lb). Refer to Illustration 468.

39. Install 1V-8031 Pin (6) into the pin bore. Refer to Illustration 465.

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Illustration 469	g01174236
Typical View of Linkage Pin in Pin Bore

40. Measure the distance between the end of the pin and the loader frame. Refer to Illustration 469.

41. Position the pin in the bore so that there is an equal space on each end of the pin. Refer to Illustration 469.

42. Apply 4C-5599 Anti-Seize Compound to the inside diameter of the collets.

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Illustration 470	g01173877
Rod Eye End of Tilt Cylinder in Tilt Lever (1) Washer (3) Collet (5) Bolt

43. Install one 8R-3931 Outside Collet (3) and one 8R-3913 inside Collet into the pin bores on the tilt lever. Refer to Illustration 465 and Illustration 470.

    Note: The collets on each end of the pin should extend the same distance from the tilt lever.

44. Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

45. Install 9X-8399 Washer (1) and 3E-8009 Bolt (5) through 8R-3931 Outside Collet (3) and 358-7033 inside Collet . Refer to Illustration 465 and Illustration 470.

46. Install 9X-8399 Washer (1) and 8T-1583 Nut (2) onto 3E-8009 Bolt (5). Refer to Illustration 465.

47. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: After the bolt is tightened, each collet should extend the same distance from the loader frame.

48. Strike the collets and the rod end of the tilt cylinder with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

49. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

50. Strike the collets and the rod end of the tilt cylinder with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

51. Tighten 3E-8009 Bolt (5) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

52. Repeat Step 1 through Step 56 for the other tilt cylinder.

53. Carefully fill the pin joint with the recommended lubricant.

54. Pin joints that are equipped with lip seals will be manually filled with grease.

55. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

56. DO NOT rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

Tilt Cylinder Lines - Install

Table 80

358-0438 Tilt Cylinder Lines Gp
Item	Qty	Part Number	Description
1	1	357-7165	Hose As
2	1	357-7164	Hose As

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Illustration 471	g02464996

1. Remove the lower two flange assemblies from the bracket. Retain the hardware. Install the two 357-7165 Hose As (1) .

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Illustration 472	g02465016

2. Remove the top two flange assemblies from the bracket. Retain the hardware. Install the two 357-7164 Hose As (2) .

Loader Bucket - Connect

Table 81

Item	Qty	Part Number	Description
−	−	7M-7456	Sealant
−	−	5P-0960	Molybdenum Grease
−	−	4C-5599	Anti-Seize Compound
245-1565 Linkage Pin and Seal
1	2	178-6248	Retainer Plate
2	2	178-6246	Seal Plate
3	2	178-6245	Pin
4	4	178-6242	Collar
5	2	147-2001	Bolt
6	6  (1)	133-2149	Shim Pack
7	2	9X-8259	Washer
8	4	9X-7699	Lip Seal
9	2	8T-4223	Hard Washer
10	8	8T-4187	Bolt
11	8	8T-4123	Hard Washer
12	2	7X-2550	Bolt

( 1 )

Use the shims in order to eliminate the gap between the pin and the flag retainer.

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Illustration 473	g01174442
Cutaway View of Pin for Loader Bucket (1) Retainer plate (2) Seal plate (3) Pin (4) Collar (5) Bolt (6) Shim pack (7) Washer (8) Lip seal (9) Hard washer (10) Bolt (11) Hard washer (12) Bolt

1. Clean the pin bores on the lift arms.

2. Clean the bores for the collars on the hinge plates of the loader bucket.

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Illustration 474	g01174550
(8) Lip seal

3. Apply 7M-7456 Sealant to the outside diameter of 9X-7699 Lip Seals (8) before installation. Refer to Illustration 474.

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Illustration 475	g01174450
Lift Arm (8) Lip seal

4. Install four 9X-7699 Lip Seals (8) into the pin bores of the lift arms. Refer to Illustration 475.

5. Verify that 9X-7699 Lip Seal (8) is seated evenly into the pin bores of the lift arms. Refer to Illustration 475.

6. Apply 4C-5599 Anti-Seize Compound to the outside diameter of 178-6242 Collar (4) .

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Illustration 476	g01174456
Hinge Plate on Left Hand Side of Loader Bucket (4) Collar

Note: Install the collars with the counterbore toward the lift arm.

7. Install four 178-6242 Collars (4) into the bores on the hinge plates of the loader bucket. Refer to Illustration 473 and Illustration 476.

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Illustration 477	g01174612
Lifting Device for Loader Bucket (A) Loader bucket

8. Attach chains or cables to loader bucket (A). Refer to Illustration 477.

9. Use a suitable lifting device in order to lift the loader bucket. Refer to Illustration 477.
   • The weight of the rock bucket is 17555 kg (38700 lb).

   • The weight of the coal bucket is 24265 kg (53500 lb).

10. Lift the loader bucket. Refer to Illustration 477.

11. Position the loader bucket in front of the lift arms.

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Illustration 478	g01174452
Left Hand Side of Loader Bucket

12. Align the pin bores in the lift arms with the bores on the hinge plates of the loader bucket. Refer to Illustration 478.

13. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

14. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

15. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

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Illustration 479	g01174453
Lifting Device for Pin on Left Hand Side of Loader Bucket (3) Pin

16. Use a suitable lifting device in order to install 178-6245 Pin (3). The weight of the pin is 115 kg (260 lb). Refer to Illustration 479.

17. Install 178-6245 Pin (3) into the collars on the hinge plates of the loader bucket and the pin bores of the lift arms. Refer to Illustration 473 and Illustration 479.

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Illustration 480	g01174457
Lifting Device for Pin on Left Hand Side of Loader Bucket (3) Pin

18. Align the flag retainer on 178-6245 Pin (3) with the slots on the hinge plates of the loader bucket. Refer to Illustration 480.

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Illustration 481	g01174454
Inside View of Bucket Pin on Right Hand Side (2) Seal plate (5) Bolt (7) Washer

19. Install 178-6246 Seal Plate (2) onto the inside of the bucket pin. Refer to Illustration 473 and Illustration 481.

20. Install 178-6246 Seal Plate (2) with the following items: 147-2001 Bolt (5) and 9X-8259 Washer (7). Refer to Illustration 473 and Illustration 481.

21. Tighten 147-2001 Bolt (5) to a torque of 2700 ± 300 N·m (2000 ± 220 lb ft). Refer to Illustration 473 and Illustration 481.

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Illustration 482	g01174458
Outside View of Bucket Pin on Left Hand Side (1) Retainer plate (6) Shim pack (9) Hard washer (10) Bolt (11) Hard washer (12) Bolt

22. Install 178-6248 Retainer Plate (1) to the bosses on the hinge plates of the loader bucket. Refer to Illustration 473 and Illustration 482.

23. Install 178-6248 Retainer Plate (1) with the following items: four 8T-4187 Bolts (10) and four 8T-4123 Plated Washers (11). Refer to Illustration 473 and Illustration 482.

24. Insert 133-2149 Shim Pack (6) in order to eliminate gaps between the flag retainer and the bracket on the hinge plate of the loader bucket. Refer to Illustration 473 and Illustration 482.

25. Install 8T-4223 Hard Washer (9) and 7X-2550 Bolt (12) through the mounting hole in 133-2149 Shim Pack (6). Refer to Illustration 473 and Illustration 482.

26. Tighten four 8T-4187 Bolts (7) to a torque of 460 ± 60 N·m (340 ± 45 lb ft). Refer to Illustration 473 and Illustration 482.

27. Tighten 7X-2550 Bolt (12) to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Refer to Illustration 473 and Illustration 482.

28. Repeat Step 12 through Step 27 for the other side of the loader bucket.

29. Carefully fill the pin joint with the recommended lubricant.

30. Pin joints that are equipped with lip seals will be manually filled with grease.

31. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

32. DO NOT rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

    Note: Move the implements slowly until all of the implements have been cycled through the full range of motion several times.

Tilt Links - Install

Table 82

Item	Qty	Part Number	Description
−	−	7M-7456	Sealant
−	−	5P-0960	Molybdenum Grease
−	−	4C-5599	Anti-Seize Compound
245-1565 Linkage Pin and Seal
1	2	245-1559	Pin
2	2	245-1548	Tilt Link
3	8	9X-8399	Washer
4	4	8T-1583	Nut
5	4	8R-3931	Collet
6	4	8R-3930	Collet
7	8	5P-2322	Lip Seal
8	2	3E-8012	Bolt
9	2	3E-8010	Bolt
10	2	1V-8031	Pin

Note: The part number for the tilt link will depend on the lift arms that are on the machine.

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Illustration 483	g01174855
Cutaway View of Pin for Tilt Link (1) Pin (2) Tilt link (3) Washer (4) Nut (6) Collet (7) Lip seal (8) Bolt

1. Clean the pin bores of the tilt links.

2. Clean the pin bores for the tilt links on the loader bucket. Refer to Illustration 483.

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Illustration 484	g01174783
(7) Lip seal

3. Apply 7M-7456 Sealant to the outside diameter of 5P-2322 Lip Seal (7) before installation. Refer to Illustration 484.

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Illustration 485	g01174881
Pin Bore in Tilt Link (2) Tilt link (7) Lip seal

4. Install two 5P-2322 Lip Seals (7) into the pin bores of 245-1548 Tilt Link (2). Refer to Illustration 485.

5. Verify that 5P-2322 Lip Seal (7) is seated evenly into the pin bores of the tilt link. Refer to Illustration 485.

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Illustration 486	g01174834
Typical View of Tilt Links

6. Orient the tilt links for proper installation.

   Note: Install the tilt links with the guard for the grease lines toward the left-hand side of the machine. The end of the tilt link with the tab should be facing upward.

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Illustration 487	g01174812
Lifting Device for Tilt Link (2) Tilt link

7. Use a suitable lifting device in order to lift 245-1548 Tilt Link (2). The weight of the tilt link is 545 kg (1200 lb). Refer to Illustration 487.

8. Lift the tilt link into position. Refer to Illustration 487.

9. Align the pin bore in the tilt link with the pin bores on the loader bucket. Refer to Illustration 487.

10. Make sure that the pin, the collars (if equipped), and the installed bearings are clean, dry, and free of rust.

11. Before the pin is installed, lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

12. For more information on assembling the pin joint, refer to Disassembly and Assembly Manual, RENR2038.

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Illustration 488	g01174835
Lifting Device for Bucket Pin (1) Pin (2) Tilt link

13. Use a suitable lifting device in order to lift 245-1559 Pin (1). The weight of the bucket pin is 70 kg (150 lb). Refer to Illustration 483 and Illustration 488.

14. Install 245-1559 Pin (1) into the pin bore on the loader bucket and the pin bore on the tilt link. Refer to Illustration 483 and Illustration 488.

15. Start the pin from the outside pin bore on the loader bucket. Refer to Illustration 483 and Illustration 488.

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Illustration 489	g01174236
Typical View of Linkage Pin in Pin Bore

16. Measure the distance between the end of the pin and the loader bucket. Refer to Illustration 489.

17. Position the pin in the pin bore so that there is an equal space on each end of the pin. Refer to Illustration 489.

18. Apply 4C-5599 Anti-Seize Compound to the inside diameter of the collets.

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Illustration 490	g01174889
Outside Collet on Right Hand Side of Loader Bucket (2) Tilt link (3) Washer (6) Collet (8) Bolt

19. Install two 8R-3930 Collets (6) into the pin bores on the loader bucket.

    Note: The collets on each end of the pin should extend the same distance from the loader bucket.

20. Apply 4C-5599 Anti-Seize Compound to the bolt threads before the bolt is installed.

21. Install 9X-8399 Washer (3) and 3E-8012 Bolt (8) through 8R-3930 Collet (6). Refer to Illustration 483 and Illustration 490.

22. Install 9X-8399 Washer (3) and 8T-1583 Nut (4) onto 3E-8012 Bolt (8). Refer to Illustration 483.

23. Tighten 3E-8012 Bolt (8) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: After the bolt is tightened, each collet should extend the same distance from the loader frame.

24. Strike the collets and the end of the tilt link with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

25. Tighten 3E-8012 Bolt (8) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

26. Strike the collets and the end of the tilt link with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

27. Tighten 3E-8012 Bolt (8) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    Note: Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

28. Repeat Step 1 through Step 27 for the other tilt link.

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Illustration 491	g01174823
Typical View of Tilt Link and Tilt Lever (2) Tilt link

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Illustration 492	g01174892
Typical View of Collet for Tilt Lever (3) Washer (5) Collet (9) Bolt

29. Repeat Step 1 through Step 27 for the tilt lever and the tilt link. Refer to Illustration 483, Illustration 491, and Illustration 492. Substitute the following items.
    • 8R-3931 Collet for 8R-3930 Collet

    • 3E-8010 Bolt for 3E-8012 Bolt

    • 1V-8031 Pin for 245-1559 Pin

30. Carefully fill the pin joint with the recommended lubricant.

31. Pin joints that are equipped with lip seals will be manually filled with grease.

32. Continue to fill the pin joint until the grease is forced out of the pin and each seal.

33. DO NOT rely on the automatic lubrication system (if equipped) in order to fill the new pin joint.

Grease Lines for the Automatic Lubrication System - Connect

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Illustration 493	g01176445
Shipping cap on Grease Line

1. Remove the shipping cap from the end of the grease lines. Refer to Illustration 493.

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Illustration 494	g01176446
Top View of Lift Arm

2. Connect the grease lines for the autolube system to the end of the lift arms. Refer to Illustration 494.

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Illustration 495	g01176447
Rod Eye End of Lift Cylinder

3. Connect the grease lines for the autolube system to the rod eye end of the lift cylinders. Refer to Illustration 495.

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Illustration 496	g01176448
Head End of Tilt Cylinder

4. Connect the grease lines for the autolube system to the head end of the tilt cylinders. Refer to Illustration 496.

5. Connect the grease lines for the autolube system to the rod eye end of the tilt cylinders.

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Illustration 497	g01176449
End of Tilt Link for Tilt Lever Arm

6. Connect the grease lines for the autolube system to the end of the tilt link that is mounted to the tilt lever arm. Refer to Illustration 497.

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Illustration 498	g01176450
Junction Block for Grease Lines on Right Hand Side of Loader Frame

7. Connect the grease lines for the autolube system to the junction block that is mounted onto the loader frame. Refer to Illustration 498.

   Note: The junction block will be located below the front section of the platform.

8. Verify that all of the grease lines for the autolube system have been connected.

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Illustration 499	g01793393

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Illustration 500	g01793413
Underside of the machine

9. Location of the clips on the lines for the automatic lubrication system

Lift Arm Position Sensor - Install

Table 83

326-2326 Lift Position Sensor and Mounting Gp
Item	Qty	Part Number	Description
1	1	5C-7261	Nut
2	1	7X-0818	Bolt
3	1	7X-0851	Nut
4	1	7X-2552	Bolt
5	1	8T-4121	Hard Washer
6	1	8T-4136	Bolt
7	1	8T-4224	Hard Washer
8	1	8T-7547	Bolt
9	3	9X-8257	Washer
10	1	100-3204	Bolt
11	1	130-5300	Clip
12	1	250-0915	Plate
13	1	266-2337	Position Sensor Gp
14	1	326-2328	Bracket As

Note: Assemble the sensor assembly before installing onto the right-hand side of the loader frame.

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Illustration 501	g02628969
Exploded View of Sensor Assembly (1) Nut (2) Bolt (3) Nut (4) Bolt (5) Hard washer (6) Bolt (7) Hard washer (8) Bolt (9) Washer (10) Bolt (11) Clip (12) Plate (13) Sensor (14) Bracket assembly

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Illustration 502	g02628939
Top View of Sensor Assembly on Loader Frame (12) Plate assembly. (14) Bracket assembly. (13) Sensor. (8) Bolt. (7) Hard washer. (2) Bolt. (1) Nut. (1) Nut (2) Bolt (7) Hard washer (8) Bolt (12) Plate (13) Sensor (14) Bracket assembly

1. Install 266-2337 Sensor (13) to the inside of 326-2328 Bracket Assembly (14) .

2. Install 266-2337 Sensor (13) with the following items: ten 8T-4224 Hard Washers (7), five 7X-0818 Bolts (2) and five 5C-7261 Nuts (1) .

3. Tighten five 7X-0818 Bolts (2) and five 5C-7261 Nuts (1) to a torque of 30 ± 5 N·m (20 ± 5 lb ft).

4. Install 130-5300 Clip (11) to the inside of 326-2328 Bracket Assembly (14) .

5. Install 130-5300 Clip (11) with the following items: 8T-4136 Bolt (6) and 8T-4121 Hard Washer (5) .

6. Tighten 8T-4136 Bolt (6) to a torque of 55 ± 10 N·m (40 ± 5 lb ft).

7. Install the wiring harness from the sensor to 130-5300 Clip (11) .

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Illustration 503	g02628941
Top View of Sensor Assembly on Loader Frame (1) Nut (2) Bolt (7) Hard washer (8) Bolt (12) Plate assembly (13) Sensor (14) Bracket assembly

8. Install 250-0915 Plate Assembly (12) onto the shaft of 266-2337 Sensor (13) .

9. Install 250-0915 Plate Assembly (12) with the following items: 8T-7547 Bolt (8) and 8T-4224 Hard Washer (7) .

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Illustration 504	g02628942
Top View of Bracket Assembly for Sensor Assembly (1) Nut (3) Nut (4) Bolt (7) Hard washer (14) Bracket assembly

10. Install 326-2328 Bracket Assembly (14) onto the right-hand side of the loader frame.

11. Install 326-2328 Bracket Assembly (14) with the following items: four 9X-8257 Washers (9) and four 7X-2552 Bolts (4) .

12. Tighten four 7X-2552 Bolts (4) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 505	g02628943
Sensor Assembly on Loader Frame and Lift Arm (2) Nut (10) Bolt (12) Plate assembly

13. Install two 7X-0851 Nuts (2) onto 100-3204 Bolt (10) before installation into the lift arm.

    Note: The nuts should be installed completely onto the threaded portion of the bolt.

14. Install 100-3204 Bolt (10) into the threaded mounting hole in the lift arm.

15. Tighten 100-3204 Bolt (10) into the lift arm.

16. Tighten two 7X-0851 Nuts (2) on the bolt.

17. Connect the wiring harness from the machine to the wiring harness from the sensor assembly.

Tilt Position Sensor - Install

Table 84

326-6473 Sensor Wiring Gp Standard Lift
Qty	Part Number	Description
1	4P-7429	Clip
4	4V-1939	Clamp
2	5P-9297	Clip
1	7G-7053	Grommet
22	8T-4121	Hard Washer
8	8T-4136	Bolt
9	8T-4137	Bolt
5	8T-4196	Bolt
19	9M-8406	Clip
4	9X-2480	Bolt
1	9X-6772	Cable Strap
4	9X-8256	Washer
5	118-9901	Spacer
2	159-8329	Bracket As
2	193-5576	Bracket As
1	254-7388	Bracket As
1	326-6464	Sensor Harness As
1	332-4530	Bracket As

Table 85

326-6474 Sensor Wiring Gp High Lift
Qty	Part Number	Description
1	4P-7429	Clip
4	4V-1939	Clamp
2	5P-9297	Clip
1	7G-7053	Grommet
20	8T-4121	Hard Washer
9	8T-4136	Bolt
7	8T-4137	Bolt
4	8T-4196	Bolt
19	9M-8406	Clip
4	9X-2480	Bolt
1	9X-6772	Cable Strap
4	9X-8256	Washer
4	118-9901	Spacer
2	159-8329	Bracket As
2	193-5576	Bracket As
1	254-7388	Bracket As
1	326-6464	Sensor Harness As
1	332-4530	Bracket As

Table 86

332-1451 Sensor Wiring Gp Extended High Lift
Qty	Part Number	Description
1	4P-7429	Clip
4	4V-1939	Clamp
2	5P-9297	Clip
1	7G-7053	Grommet
3	8B-0544	Spacer
23	8T-4121	Hard Washer
8	8T-4136	Hard Washer
9	8T-4137	Hard Washer
2	8T-4182	Hard Washer
4	8T-4196	Hard Washer
19	9M-8406	Clip
4	9X-2480	Bolt
1	9X-6772	Bolt
4	9X-8256	Bolt
4	118-9901	Spacer
2	159-8329	Bracket As
2	193-5576	Bracket As
1	254-7388	Bracket As
1	326-6467	Sensor Harness As
1	332-4530	Bracket As

Table 87

332-1450 Sensor Wiring Gp Super High Lift
Qty	Part Number	Description
1	4P-7429	Clip
4	4V-1939	Clamp
2	5P-9297	Clip
2	7E-5639	Spacer
1	7G-7053	Grommet
21	8T-4121	Hard Washer
8	8T-4136	Bolt
8	8T-4137	Bolt
1	8T-4182	Bolt
4	8T-4196	Bolt
18	9M-8406	Clip
4	9X-2480	Bolt
1	9X-6772	Cable Strap
4	9X-8256	Washer
4	118-9901	Spacer
2	159-8329	Bracket As
2	193-5576	Bracket As
1	254-7388	Bracket As
1	326-6466	Control Harness As
1	332-4530	Bracket As

Note: All linkage groups above use the 333-9155 Position Sensor Gp . Parts are listed below.

Table 88

333-9155 Position Sensor Gp
Qty	Part Number	Description
6	6V-8197	Bolt
1	7X-2562	Bolt
1	7X-2564	Bolt
5	8T-4123	Washer
2	8T-4132	Nut
6	8T-4139	Bolt
12	8T-4223	Hard Washer
1	100-8255	Bolt
1	333-6022	Guard As
1	333-6132	Plate
1	333-9220	Plate

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Illustration 506	g02174475
(1) 333-6022 Guard As (2) 7X-2562 Bolt (3) 7X-2564 Bolt (4) 8T-4123 Washer

1. Use the listed hardware in order to install 333-6022 Guard As (1) onto the lever.

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Illustration 507	g02174484
Sensor mounting group 333-9156 Tilt Position Sensor and Mounting Gp (5) 130-5300 Clip (6) 266-2337 Position Sensor Gp (7) 333-9215 Bracket As (8) 333-9218 Plate As (9) 5C-7261 Nut (10) 7X-0818 Bolt (11) 8T-4121 Hard Washer (12) 8T-4136 Bolt (13) Use two 8T-4224 Hard Washers for each bolt for the sensor -- one under the nut and one under the bolt. (14) 8T-7547 Bolt

2. Use the listed hardware in order to assemble the sensor mounting group.

   Assemble 266-2337 Position Sensor Gp (6) onto 333-9215 Bracket As (7). Use 130-5300 Clip (5) in order to fasten the plug connector onto the boss.

   Mount 333-9218 Plate As (8) onto 266-2337 Position Sensor Gp (6) .

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Illustration 508	g02174488
(15) 100-8255 Bolt (17) 221-2944 Plate (18) 333-9215 Bracket As (19) 5C-9553 Bolt (20) 8T-4132 Nut (21) 8T-4139 Bolt (22) 8T-4223 Hard Washer (23) 9X-8256 Washer

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Illustration 509	g02174523
(15) 100-8255 Bolt (20) 8T-4132 Nut (A) 29 mm (1.14 inch) minimum thread engagement

3. Install the sensor on the linkage

   Use bolts (21) and washers (22) in order to mount bracket assembly (18) onto block (16) .

   Align the sensor arm and install bolt (15) and locknuts (20). Ensure that bolt (15) has a minimum thread engagement of 29 mm (1.14 inch).

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Illustration 510	g02174528
(B) 5 mm (0.2 inch) gap between plate and crossmember (18) 333-9215 Bracket As (24) 333-9220 Plate (21) 8T-4139 Bolt (22) 8T-4223 Hard Washer

4. Use two bolts (21) and two washers (22) in order to assemble 333-9220 Plate (24) onto bracket assembly (18) .

   Adjust 333-9220 Plate (24) in order to establish a 5 mm (0.2 inch) gap (B) between plate (24) and the crossmember.

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Illustration 511	g02174710
(25) 333-6132 Plate (26) 6V-8197 Bolt (22) 8T-4223 Hard Washer

5. Use six bolts (26) and six washers (22) in order to mount 333-6132 Plate (25) onto the guard assembly.

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Illustration 512	g02174714
Refer to Tables 84, 85, 86, and 87 for the correct parts list. (27) 193-5576 Bracket As (17) 221-2944 Plate (28) Sensor Harness Assembly (18) 333-9215 Bracket As (30) 4P-7429 Clip (19) 5C-9553 Bolt (20) 5P-9297 Clip (31) 7G-7053 Grommet (11) 8T-4121 Hard Washer (12) 8T-4136 Bolt (32) 8T-4137 Bolt (33) 9M-8406 Clip (34) 9X-6772 Cable Strap (13) 9X-8256 Washer

6. Use bolts (19) and washers (13) in order to install plate (17) onto bracket assembly (18) .

   Use the listed hardware in order to attach and secure the linkage jumper.

   Note: Use a 5C-9553 Bolt in order to install 4P-7429 Clip (30) .

Installation of the Harnesses for the Sensors

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Illustration 513	g02188635
View of the overall routing of the wire for the standard, extended, and high lift

1. Connect the wire for the sensor. Use bolts and washers in order to install plate onto bracket assembly .Refer to Illustration 513 for reference to the overall routing of 326-6464 Sensor Harness As , 326-6465 Sensor Harness As , and the 326-6466 Control Harness As .

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Illustration 514	g02188653
(1) 193-5576 Bracket As (2) 8T-4121 Hard Washer (3) 8T-4136 Bolt (4) 9M-8406 Clip

2. Use the listed hardware in order to install clips (75) onto the two bosses. These clips will support the harness assembly that is attached to the tilt sensor.

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Illustration 515	g02188654
View (A)

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Illustration 516	g02188655
Standard Lift machines will use 326-6464 Sensor Harness As and High Lift machines will use 326-6465 Sensor Harness As . Extended High Lift machines will use the 326-6466 Control Harness As . (A) Existing wire harness (B) Location of existing hardware (5) 326-6464 Sensor Harness As (6) 326-6465 Sensor Harness As (7) 5P-9297 Clip (2) 8T-4121 Hard Washer (3) 8T-4136 Bolt (4) 9M-8406 Clip

3. Continue installing the harness. Use the parts listed above.

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Illustration 517	g02188674
Location (B)

4. Use the hardware that is listed and the existing hardware in order to secure the linkage jumper that is shown in Illustration 516 and Illustration 517.

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Illustration 518	g02188675

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Illustration 519	g02188676
Location of area (C) . (8) 254-7388 Bracket As (9) 332-4530 Bracket As (10) 4V-1939 Clamp (11) 5V-6439 Plate (12) 7X-2534 Bolt (2) 8T-4121 Hard Washer (3) 8T-4136 Bolt (13) 9X-8256 Washer

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Illustration 520	g02188677
(10) 4V-1939 Clamp (11) 5V-6439 Plate (12) 7X-2534 Bolt (13) 9X-8256 Washer

5. Refer to Illustration 518,519 and 520. Use the listed hardware in order to mount two clamps on the front frame near the A-pin. Assemble clamps (10) over the green tape on the harness.

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Illustration 521	g02188693

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Illustration 522	g02188694
Outside of the lift arm

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Illustration 523	g02188695
Inside of the lift arm

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Illustration 524	g02188696
(14) 118-9901 Spacer (2) 8T-4121 Hard Washer (15) 8T-4196 Bolt (16) 9M-8406 Clip

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Illustration 525	g02188698
(14) 118-9901 Spacer (12) 159-8329 Bracket As (2) 8T-4121 Hard Washer (15) 8T-4196 Bolt (16) 9M-8406 Clip

6. Refer to Illustration 521 through Illustration 525. Use the listed hardware in order to secure the linkage jumper around the lift arm.

   Note: You will use two 159-8329 Bracket Assemblies (17) in order to secure the linkage jumper as shown in Illustration 525.

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Illustration 526	g02188713

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Illustration 527	g02188714
(2) 8T-4121 Hard Washer (3) 8T-4136 Bolt (4) 9M-8406 Clip

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Illustration 528	g02188715
(4) 9M-8406 Clip

7. Refer to Illustration 526 and Illustration 528. Use the listed hardware in order to install three 9M-8406 Clips (4) .

   Use the existing hardware from the grease lines in order to install one clip (4). The clip will face toward the lift arm and under the clips for the grease line.

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Illustration 529	g02188717
(Std) Routing for the jumper on a machine that is equipped with standard lift (High) Routing for the jumper on a machine that is equipped with high lift (Extended) Routing for the jumper on a machine that is equipped with extended high lift (2) 8T-4121 Hard Washer (3) 8T-4136 Bolt (4) 9M-8406 Clip

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Illustration 530	g02188718
(4) 9M-8406 Clip

8. Use the listed hardware in order to install clips (4) and fasten the harness onto the lift arm.

   Note: The clip on the standard lift machine will face toward the lift arm under the clips for the grease line.

335-4304 Harness As (Tilt) Installation

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Illustration 531	g02192024
Location of Area L

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Illustration 532	g02192025
View of Area L (4) 130-5300 Clip (33) 335-4304 Harness As (Tilt) (77) 9X-6772 Cable Strap

1. Connect 335-4304 Harness As (Tilt) (19) into the existing connector on the front harness. Use the existing hardware in order to install 130-5300 Clip (18) onto the existing boss.

   Use tie straps along the front harness in order to secure the harness.

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Illustration 533	g02192026
Routing for the 335-4304 Harness As (Tilt)

2. The routing for the tilt jumper will follow the front harness through the frame. Strap the tilt jumper to the front harness in order to secure the jumper.

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Illustration 534	g02192028
(K) Position of the old connector (K1) Position of the new connector (L) Old harness routing (L1) New harness routing (19) 335-4304 Harness As (20) 9X-6772 Cable Strap

3. The front harness connector for the old proximity switch is reused for the new rotational tilt sensor. Reroute the front harness connector in order to make the connection to tilt jumper (19) .

Mirrors - Install

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Illustration 535	g02629878

1. 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 536	g02629879

2. 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.

3. 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 537	g02629896
(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

4. Install mirrors on the handrails on each side of the cab

Heated Mirrors (if equipped)

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Illustration 538	g02629900
202-8649 Mirror As (Heated mirror) (1) 9X-6772 Cable Strap (2) 130-5301 Clip (3) 4D-8123 Clip (4) Two mounting bolts

1. 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. 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.

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

Illustration 539	g02684316
(5) Heated mirror switch

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

Product Link System - Install (if equipped)

Installing the 360-1631 Communication Installation Ar (CELLULAR)

Table 89

360-1631 Communication Installation Ar (CELLULAR)
360-1635 Communication Wiring Gp (PRODUCT LINK)
Item	Qty	Part Number	Description
1	4	9X-6772	Cable Strap
2	1	9X-9365	Bracket
3	1	270-8544	Bracket As
4	1	346-9376	Antenna As
5	1	453-0928	Cable As
6	1	132-5789	Clip
7	4	8T-4121	Hard Washer
8	1	8T-4133	Nut
9	3	8T-4136	Bolt
360-1685 Communication Electronic Control Module (CELLULAR)
10	8	8C-5607	Isolation Mount
11	4	8C-5608	Spacer
12	1	334-1599	Cable
13	1	336-6910	Cable
14	1	336-6911	Plate
15	1	351-8492	Electronic Control Module
16	4	204-0813	Bolt
17	2	9X-6165	Washer
18	5	7K-1181	Cable Strap

Installing 360-1635 Communication Wiring Gp (PRODUCT LINK)

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Illustration 540	g03375195
(2) 9X-9365 Bracket (3) 270-8544 Bracket As (7) 8T-4121 Hard Washer (9) 8T-4136 Bolt

1. Assemble Bracket As (3) to the right side of the cab. Use two Hard Washers (7) and two Bolts (9). Assemble Washer and Bolt through Bracket (2) and into the forward hole of Bracket As (3) .

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Illustration 541	g03375210
(4) 346-9376 Antenna As (6) 132-5789 Clip (7) 8T-4121 Hard Washer (8) 8T-4133 Nut

2. Assemble Clip (6) to the bracket. Use one Hard Washer (7) and one Nut (8) .

3. Assemble Antenna As (4) to the bracket. Torque the nut at the bottom of Antenna As (4) to 5 ± 0.5 N·m (3.69 ± 0.37 lb ft).

   Note: Position antenna with puck facing outward. Refer to Illustration 541

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Illustration 542	g03375223
(1) 9X-6772 Cable Strap (5) 453-0928 Cable As

4. Connect Cable As (5) to antenna. Use four Cable Straps (1) to secure Cable As. Refer to Illustration 542.

   Note: Distribute the cable slack evenly over the length of the installation.

   Note: Do Not Coil the Cable

Installing 360-1685 Communication Electronic Control Module (CELLULAR)

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Illustration 543	g03375244
(D) Connect MC-C3 to Pin 1 R991-OR (E) Connect MC-T10 to C209-BK (10) 8C-5607 Isolation Mount (11) 8C-5608 Spacer (15) 351-8492 Electronic Control Module (16) 204-0813 Bolt (17) 9X-6165 Washer

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Illustration 544	g03375245
(12) 334-1599 Cable (13) 336-6910 Cable (14) 336-6911 Plate (18) 7K-1181 Cable Strap

1. Install Electronic Control Module (15) at the lower, right, front of the operator station. Use eight Isolation Mounts (10), four Spacers (11), four Bolts (16), two Washers (17), and one Plate (14). Refer to Illustrations 543 and 544.

2. At Point (D), connect MC-C3 to Pin 1 R991-OR. Final torque for this connection is 6.1 ± 1 N·m (5.0 ± 0.7 lb ft). Refer to Illustration 543.

3. At Point (E), connect MC-T10 to C209-BK. Final torque for this connection is 2.5 ± 0.25 N·m (1.8 ± 0.2 lb ft). Refer to Illustration 543

4. Route Cable (12) and Cable (13) and secure with five Cable Strap (18). Final torque for these connections is 0.9 ± 1 N·m (8.0 ± 8.9 lb in). Refer to Illustration 544.

   Note: Wrap the coaxial cables in tape at each Cable Strap location

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Illustration 545	g03379045
(F) 313 mm (12.32 inch) (G) 314 mm (12.36218 inch) (H) 92 mm (3.62 inch) (K) 69 mm (2.72 inch) (K) 10.3 mm (0.41 inch) hole for TNC connector (L) 10.3 mm (0.41 inch) hole for reverse polarity TNC connector (M) Roof Top

5. Drill two 10.3 mm (0.41 inch) holes for mounting the TNC connectors. Refer to Illustration 545.

   Note: Final torque assembly for the TNC connectors is 10.5 ± 2.5 N·m (7.8 ± 1.8 lb ft)

Installing the 360-1632 Monitor Control Ar (VIMS 3G) (no PRODUCT LINK)

Table 90

360-1686 Monitor Electronic Control Module (VIMS 3G)
Item	Qty	Part Number	Description
1	8	8C-5607	Isolation Mount
2	4	8C-5608	Spacer
3	1	336-6911	Plate
4	4	204-0813	Bolt
5	1	285-1141	Monitor Application Gp
6	2	9X-6165	Washer

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Illustration 546	g03379376
(B) Connect MC-C3 to Pin 1 R991-OR (C) Connect MC-T10 to C209-BK (1) 8C-5607 Isolation Mount (2) 8C-5608 Spacer (3) 336-6911 Plate (4) 204-0813 Bolt (5) 285-1141 Monitor Application Gp (6) 9X-6165 Washer

1. Install Monitor Application Gp (5) at the lower, right, front of the operator station. Use four Isolation Mounts (1), two Spacers (2), two Bolts (4), two Washers (6), and one Plate (3). Refer to Illustration 546.

2. At Point (B), connect MC-C3 to Pin 1 R991-OR. Final torque for this connection is 6.1 ± 1 N·m (5.0 ± 0.7 lb ft). Refer to Illustration546.

3. At Point (C), connect MC-T10 to C209-BK. Final torque for this connection is 2.5 ± 0.25 N·m (1.8 ± 0.2 lb ft). Refer to Illustration 546.

Installing the 360-1637 Communication Installation Ar PRODUCT LINK (Satellite)

Table 91

360-1637 Communication Installation Ar
360-1634 Communication Wiring Gp
Item	Qty	Part Number	Description
1	4	9X-6772	Cable Strap
2	1	9X-9365	Bracket
3	1	270-8544	Bracket As
4	1	453-0928	Cable As
5	1	351-8485	Antenna As
6	1	132-5789	Clip
7	4	8T-4121	Hard Washer
8	1	8T-4133	Nut
9	3	8T-4136	Bolt
360-1684 Communication Electronic Control Module
10	8	8C-5607	Isolation Mount
11	4	8C-5608	Spacer
12	1	334-1599	Cable
13	1	336-3545	Communication Radio Gp
14	1	336-6910	Cable
15	1	336-6911	Plate
16	4	186-0815	Bolt
17	4	204-0813	Bolt
18	1	285-1141	Monitor Application Gp
19	2	9X-6165	Washer
20	4	9X-8256	Washer
21	5	7K-1181	Cable Strap

Installing 360-1634 Communication Wiring Gp

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Illustration 547	g03379457
(2) 9X-9365 Bracket (3) 270-8544 Bracket As (7) 8T-4121 Hard Washer (9) 8T-4136 Bolt

1. Assemble Bracket As (3) to the right side of the cab. Use two Hard Washers (7) and two Bolts (9). Assemble Washer and Bolt through Bracket (2) and into the forward hole of Bracket As (3) .

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Illustration 548	g03379462
(5) 351-8485 Antenna As (6) 132-5789 Clip (7) 8T-4121 Hard Washer (8) 8T-4133 Nut

2. Assemble Clip (6) to the bracket. Use one Hard Washer (7) and one Nut (8) .

3. Assemble Antenna As (5) to the bracket. Torque the nut at the bottom of Antenna As (5) to 5 ± 0.5 N·m (3.69 ± 0.37 lb ft).

   Note: Position antenna with puck facing outward. Refer to Illustration 548

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Illustration 549	g03379552

4. Connect Cable As (4) to antenna. Use four Cable Straps (1) to secure Cable As. Refer to Illustration 549.

   Note: Distribute the cable slack evenly over the length of the installation.

   Note: Do Not Coil the Cable

Installing 360-1684 Communication Electronic Control Module

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Illustration 550	g03379559
(D) Connect MC-C3 to Pin 1 R991-OR (E) Connect MC-T10 to C209-BK (10) 8C-5607 Isolation Mount (11) 8C-5608 Spacer (17) 204-0813 Bolt (18) 285-1141 Monitor Application Gp (19) 9X-6165 Washer

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Illustration 551	g03379564
(12) 334-1599 Cable (14) 336-6910 Cable (15) 336-6911 Plate (21) 7K-1181 Cable Strap

1. Install Monitor Application Gp (18) at the lower, right, front of the operator station. Use two Isolation Mounts (10), four Spacers (11), two Bolts (17), two Washers (19), and one Plate (15). Refer to Illustration 550.

2. At Point (B), connect MC-C3 to Pin 1 R991-OR. Final torque for this connection is 6.1 ± 1 N·m (5.0 ± 0.7 lb ft). Refer to Illustration 550.

3. At Point (C), connect MC-T10 to C209-BK. Final torque for this connection is 2.5 ± 0.25 N·m (1.8 ± 0.2 lb ft). Refer to Illustration 550.

Radio Antenna - Install

Note: The following procedure applies only to machines that are equipped with a radio.

Table 92

239-4054 Antenna Mounting Gp
Item	Qty	Part Number	Description
1	4	1V-6341	Seal
2	4	6B-4196	Thrust Washer
3	2	9U-2327	Connector
4	2	9U-2328	Coaxial Cable As
5	1	9U-2329	Coaxial Cable As
6	2	9U-2330	Antenna Mount
7	1	9U-2331	Antenna As
8	1	9U-2332	Antenna As
9	1	9U-2334	Coaxial Cable As
10	1	4P-7581	Clip
11	4	7K-1181	Cable Strap
12	1	8T-4121	Hard Washer
13	1	8T-4137	Bolt

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Illustration 552	g03362846
View as facing the machine (5) 9U-2329 Coaxial Cable As (6) 9U-2330 Antenna Mount (7) 9U-2331 Antenna As (8) 9U-2332 Antenna As (9) 9U-2334 Coaxial Cable As

1. Assemble two 9U-2330 Antenna Mounts (6) to the ROPS canopy. Refer to Illustration 552.

2. Assemble 9U-2332 Antenna As (8) to the 9U-2330 Antenna Mount (6) on the left-hand side of the ROPS canopy. Refer to Illustration 552.

3. Assemble 9U-2334 Coaxial Cable As (9) to the 9U-2330 Antenna Mount (6) on the left-hand side of the ROPS canopy. Secure the 9U-2334 Coaxial Cable As (9) in two locations, using two 7K-1181 Cable Straps (11). Refer to Illustration 552.

4. Assemble 9U-2331 Antenna As (8) to the 9U-2330 Antenna Mount (6) on the right-hand side of the ROPS canopy. Refer to Illustration 552.

5. Assemble 9U-2329 Coaxial Cable As (5) to the 9U-2330 Antenna Mount (6) on the right-hand side of the ROPS canopy. Refer to Illustration 552.

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Illustration 553	g03362911
(5) 9U-2329 Coaxial Cable As (9) 9U-2334 Coaxial Cable As (10) 4P-7581 Clip (11) 7K-1181 Cable Strap (12) 8T-4121 Hard Washer (13) 8T-4137 Bolt

6. Assemble one 4P-7581 Clip (10) to the bottom of the ROPS canopy. Use one 8T-4121 Hard Washer (12) and one 8T-4137 Bolt (13). Refer to Illustration 553.

7. Secure 9U-2334 Coaxial Cable As (9) and 9U-2329 Coaxial Cable As (5) to 4P-7581 Clip (10) using one 7K-1181 Cable Strap (11). Refer to Illustration 553.

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Illustration 554	g03362919
(5) 9U-2329 Coaxial Cable As (9) 9U-2334 Coaxial Cable As (11) 7K-1181 Cable Strap

8. Secure 9U-2334 Coaxial Cable As (9) and 9U-2329 Coaxial Cable As (5) together using one 7K-1181 Cable Strap (11). Refer to Illustration 554.

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Illustration 555	g03362850
(1) 1V-6341 Seal (2) 6B-4196 Thrust Washer (3) 9U-2327 Connector (4) 9U-2328 Coaxial Cable As

9. Assemble one 9U-2327 Connector (3) to the end of 9U-2334 Coaxial Cable As (9). Assemble one 6B-4196 Thrust Washer (2) and one 1V-6341 Seal (1) to 9U-2327 Connector (3). Place Connector (3) through one of the hole in the roof of the operator station. Connect 9U-2329 Coaxial Cable As (5) .

   Note: Repeat Step 9 for 9U-2334 Coaxial Cable As (9) in the second hole.

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Illustration 556	g03362849
(4) 9U-2328 Coaxial Cable As

10. From the inside of the operator station, assemble one 6B-4196 Thrust Washer (2) and one 1V-6341 Seal (1) to 9U-2327 Connector (3). Connect one 9U-2328 Coaxial Cable As (4) to the end of each 9U-2327 Connector (3) .

Access Cover for the ROPS - Install

Table 93

368-9169 Access Cover Gp
Item	Qty	Part Number	Description
1	1	258-6582	Cover
2	4	8T-4897	Washer
3	4	8T-4137	Bolt

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Illustration 557	g01176664
Access Cover for ROPS (1) Cover (2) Washer (3) Bolt

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Illustration 558	g01176642
Rear View of ROPS (1) Cover (2) Washer (3) Bolt

1. Verify that all wiring harnesses are properly secured to the ROPS.

2. Install 258-6582 Cover (1) onto the rear of the ROPS. Refer to Illustration 557 and Illustration 558.

3. Install 258-6582 Cover (1) with the following items: four 8T-4897 Washers (2) and four 8T-4137 Bolts (3). Refer to Illustration 557 and Illustration 558.

4. Tighten four 8T-4137 Bolts (3) to a torque of 55 ± 10 N·m (40 ± 5 lb ft). Refer to Illustration 557 and Illustration 558.

CAT detect - Install (if equipped)

Table 94

363-7177 Sensor Wiring Gp (RADAR)
Item	Qty	Part Number	Description
1	6	9X-6772	Cable Strap
2	3	363-7101	Bracket
3	1	365-5971	Box Harness As
4	3	374-3605	Object Detection Box Gp
5	12	198-4775	Hard Washer
6	3	2M-3432	Grommet
7	6	5P-1076	Hard Washer
8	6	8T-4139	Bolt
9	12	8T-4971	Bolt
10	12	9X-6165	Washer

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Illustration 559	g03364499
(1) 9X-6772 Cable Straps (3) 365-5971 Box Harness As

1. Assemble 365-5971 Box Harness As (3) to the under side of the radiator. Secure the harness with six 9X-6772 Cable Straps (1). Connect harness to chassis harness at Point (A) .

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Illustration 560	g03364517
(6) 2M-3432 Grommets

2. Assemble three 2M-3432 Grommets (6) to the harness tails and seat the Grommets. Refer to Illustration 560.

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Illustration 561	g03364544
(2) 363-7101 Bracket (3) 374-3605 Object Detection Box Gp (5) 198-4775 Hard Washer (7) 5P-1076 Hard Washer (8) 8T-4139 Bolt (9) 8T-4971 Bolt (10) 9X-6165 Washer

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Illustration 562	g03364540
(3) 374-3605 Object Detection Box Gp

3. Mount three Brackets (2) to the bumper. Use six Washers (7) and six Bolts (8) .

4. Assemble three Object Detection Box Gp (4) to three Brackets (2). Use 12 Hard Washers (5), 12 Bolts (9), and 12 Washers (10) .

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Illustration 563	g03374919
(9) 8T-4971 Bolt

5. Orient the outer two Object Detection Box Gp to 30°. Tighten the four Bolts (9) on each bracket.

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Illustration 564	g03374953

6. Orient the center Object Detection Box Gp to 10°. Tighten the four Bolts (9) on the bracket.

Transmission Guards - Install

Table 95

336-0465 Bottom Guard Gp
Item	Qty	Part Number	Description
1	1	358-0745	Guard
2	1	358-0744	Guard
8X-1736 Bottom Guard Fastener Group
3	17	7X-2562	Bolt
4	17	8T-5439	Washer

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Illustration 565	g01176474
Right Hand Side and Bottom View of Rear Frame (1) Guard (2) Guard (3) Bolt (4) Washer

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Illustration 566	g01176467
Bottom View of Rear Frame (1) Guard (2) Guard (3) Bolt (4) Washer

1. Use a lift truck or a suitable lifting device in order to lift the 358-0745 Guard (1) into position. The weight of the guard is 105 kg (230 lb).

2. Install 358-0745 Guard (1) onto the bottom of the rear frame. Refer to Illustration 565 and Illustration 566.

   Note: This guard will be located to the rear of the articulation joint.

3. Install 358-0745 Guard (1) with the following items: seven 7X-2562 Bolts (3) and seven 8T-5439 Washers (4). Refer to Illustration 565 and Illustration 566.

4. Use a lift truck or a suitable lifting device in order to lift the 358-0744 Guard (2) into position. The weight of the guard is 170 kg (375 lb).

5. Install 358-0744 Guard (2) onto the bottom of the rear frame. Refer to Illustration 565 and Illustration 566.

   Note: This guard will be located in front of the rear axle.

6. Install 358-0744 Guard (2) with the following items: ten 7X-2562 Bolts (3) and ten 8T-5439 Washers (4). Refer to Illustration 565 and Illustration 566.

7. Tighten 17 7X-2562 Bolts (3) to a torque of 460 ± 60 N·m (340 ± 45 lb ft). Refer to Illustration 565 and Illustration 566.

Crankcase Guard - Install

Note: The following procedure applies only to machines that are equipped with 109-0036 Crankcase Guard .

Table 96

336-0465 Bottom Guard Gp
Item	Qty	Part Number	Description
1	1	358-0743	Guard
2	1	358-0741	Guard
3	18	7X-2562	Bolt
4	18	8T-5439	Washer

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Illustration 567	g01176549
Right Hand Side and Bottom View of Rear Frame (1) Guard (2) Guard (3) Bolt (4) Washer

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Illustration 568	g01176550
Bottom View of Rear Frame (1) Guard (2) Guard (3) Bolt (4) Washer

1. Use a lift truck or a suitable lifting device in order to lift the 358-0743 Guard (1) into position. The weight of the guard is 130 kg (285 lb).

2. Install 358-0743 Guard (1) onto the bottom of the rear frame. Refer to Illustration 567 and Illustration 568.

   Note: This guard will be located to the rear of the rear axle.

3. Install 358-0743 Guard (1) with the following items: eight 7X-2562 Bolts (3) and eight 8T-5439 Washers (4). Refer to Illustration 567 and Illustration 568.

4. Use a lift truck or a suitable lifting device in order to lift the 358-0741 Guard (2) into position. The weight of the guard is 160 kg (350 lb).

5. Install 358-0741 Guard (2) onto the bottom of the rear frame. Refer to Illustration 567 and Illustration 568.

   Note: This guard will be located in front of the bumper assembly.

6. Install 358-0741 Guard (2) with the following items: ten 7X-2562 Bolts (3) and ten 8T-5439 Washers (4). Refer to Illustration 567 and Illustration 568.

7. Tighten 18 8T-6430 Bolts (3) to a torque of 460 ± 60 N·m (340 ± 45 lb ft). Refer to Illustration 567 and Illustration 568.

Procedure for Starting the Machine

Activate the Batteries

Table 97

Parts that are required in order to activate the batteries
Item	Qty	Part Number	Description
A	2	319-0810	Battery and Wiring Gp

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Illustration 569	g01138824

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Illustration 570	g01389494
View of batteries that are installed

1. Open the battery compartment of the left side of the cab platform. Locate the two batteries (A) that are in the battery compartment on the platform.

2. Make sure that battery lockout is engaged, or in the OFF position.

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Illustration 571	g01389609
View of activation of battery (A)

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

Enter the Attachment Code

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

2. Permit only one operator on the machine. Keep all other personnel away from the machine.

3. Connect Caterpillar ET to the machine.

4. Turn the electrical disconnect switch to the ON position.

5. Turn the engine start switch to the ON position.

   Note: DO NOT turn the engine start switch to the START position.

6. Enter the attachment code by using the Electronic Technician.

   Note: The machine will not communicate with the transmission ECM if the attachment code is not entered.

7. Enter "CONFIGURE"

8. Enter "INSTALL CONFIGURATION"

9. Enter "INSTALL CONFIGURATION ON MACHINE"

10. Enter "ATTACH".

11. Press "OK".

12. Enter the appropriate attachment code. Refer to Table 98.
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    Table 98

    Machine Configuration	Attachment Code
    Standard Lift	1
    High Lift	2
    Super High Lift	3
    Extended High Lift	4

13. Press "OK".

14. Enter the attachment code again.

15. Press "OK".

Inspect the Machine Before Starting the Machine

1. Connect the steering frame lock link.

Note: Refer to Operation and Maintenance Manual, SEBU7885, "Lubricant Viscosities and Refill Capacities" for information on the fluids.

2. Fill the fuel tank to 25 percent capacity in order to keep the weight to a minimum.

3. Check the engine oil level.

4. Maintain the engine oil at the correct level.

5. Fill both of the radiators with coolant.

6. Fill all three of the hydraulic tanks with hydraulic fluid.

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

8. Check the oil level in the front pump drive.

9. Maintain the oil at the correct level.

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

11. Fill the case drain lines with oil.

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

13. Fill the case drain lines with oil.

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

15. Fill the case drain line with oil.

16. Fill the transmission with oil.

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

18. Use an external source in order to fill the air tank. The engine will need 800 kPa (115 psi) in order to start.

    Note: After the machine has been operated, the engine will only require 650 kPa (95 psi) in order to start. The capacity of the air tank will allow the engine to be started three times.

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

    Note: Refer to Operation and Maintenance Manual, SEBU7885, "Walk-Around Inspection".

20. Pull the remote engine stop switch.

21. Hold out the switch.

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

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

24. Repeat Step 20 and Step 22 three times.

25. Check all of the fluid levels.

26. Maintain the fluids at the correct level.

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

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

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

29. Stop the engine and check all of the fluid levels.

30. Maintain the fluids at the correct level.

31. Repeat Step 28 and Step 29 until the fluid levels do not change.

Operate the Automatic Lubrication System Manually

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

2. Enter the manual lubrication operation by pushing the manual lubrication button.

3. Repeat Step 2 until grease is visible from the linkage pins.

4. The display screen should be clear of any other messages.

5. Press "OK".

6. Enter "SERV".

7. Press "OK".

8. The display will go to the calibration mode.

9. The first service that is shown will be "MANUAL LUBRICATION".

10. Press "OK" in order to accept the task.

11. Press "OK" again in order to start the cycle.

12. After the cycle has been completed, the display screen will return to the normal mode.

13. Repeat Step 4 through Step 12 until grease is visible from the linkage pins.

Break-In Procedure (Implement Cylinders)

Illustration 572	g01881056
(A) Lift cylinders (B) Tilt cylinders

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Illustration 573	g01881143
Top view of tilt cylinders (1) The Tap that is used in order to purge off the air

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

2. Check the hydraulic oil level.

3. Run the engine at low idle.

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

4. Place the lift cylinders in the assembled position.

5. Extend the lift cylinders to 75% of the full stroke.

6. Retract the lift cylinder to 12.5% of the full stroke after 4 seconds of waiting.

7. Repeat Step 4 through Step 6 after 4 seconds of waiting.

8. Repeat Step 4 through Step 6 for five cycles. Allow the cylinders to extend and retract. Change directions after a minimum of 4 seconds of waiting.

   Note: Do not allow the relief valve to open.

9. Repeat Step 4 through 8 for the tilt cylinders.

10. Fully retract the lift cylinders.

11. Extend the tilt cylinders to 50% of the full stroke.

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

13. Install the cap for the implement hydraulic tank.

Break-In Procedure (Pin)

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Illustration 574	g00769254
Level Position of Linkage Pins (A) Linkage pin (B) Linkage pin

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

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

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

4. On machines that are equipped with an automatic lubrication system, the system can be activated manually in order to grease the new pin joints. Refer to ""Operate the Automatic Lubrication System Manually" " in this Special Instruction.

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

6. Slowly raise the boom to the level position.

7. Check that pins (A) and (B) are at the same height.

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

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

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

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

12. Lower the loader bucket to the ground.

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

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

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

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

17. Slowly raise the boom to maximum lift height.

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

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

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

21. Lower the loader bucket to the ground.

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

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

24. Refer to Step 2.

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

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

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

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

29. Raise the loader bucket to the level position.

30. Dump the loader bucket.

31. Lower the loader bucket to the ground.

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

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

34. Refer to Step 2.

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

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

37. Raise the loader bucket to maximum lift height.

38. Dump the loader bucket.

39. Lower the loader bucket to the ground.

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

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

42. Refer to Step 2.

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

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

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

46. Raise the loader bucket to maximum lift height.

47. Dump the loader bucket.

48. Lower the loader bucket to the ground.

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

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

51. Refer to Step 2.

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

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

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

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

56. Maintain the fluids at the correct level.

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

Operation after Break-In Procedure (Pin)

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

2. Check after the pin joint is replaced.

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

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

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

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

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

Brakes - Purge

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, 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.

Illustration 575	g00769225
Right Hand Side and Front of Machine (1) Brake purge valve

Illustration 576	g00769227
Left Hand Side and Front of Machine (2) Brake purge valve

Illustration 577	g00769228
Right Hand Side and Rear of Machine (3) Brake purge valve

Illustration 578	g00769229
Left Hand Side and Rear of Machine (4) Brake purge valve

1. Place a container under the brake valve in order to contain any brake fluid that is lost when the brakes are purged.

2. Open the brake purge valve (1) on the right front brake.

3. Depress the brake pedal in the cab.

4. Close the brake purge valve (1) .

5. Release the brake pedal.

6. Repeat Step 2 through Step 3 until all of the air is purged from the brake line.

7. Repeat Step 1 through Step 6 for the brake purge valves on the other three brakes.

Break-In Procedure (Steering Cylinders)

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

2. Check the hydraulic oil level.

3. Run the engine at low idle.

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

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

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

Steering Neutralizer Valve - Adjust

Note: The steering neutralizer valves prevent contact between the rear frame and the loader frame.

Note: Remove the steering lock link before the neutralizer valve is adjusted.

Initial Adjustment of the Steering Neutralizer Valve

1. Park the machine on a surface that is hard and smooth.

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Illustration 579	g00769252
Left Hand Side of Machine on Upper Pin of Articulation Joint (1) Stud assembly (2) Steering neutralizer valve

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Illustration 580	g00769253
View of Left Turn Frame Stop (3) Steering stop on loader frame (4) Steering stop on rear frame

2. Turn the machine all the way to the left.

3. Adjust stud assembly (1) in order to set the gap between the steering stop on the loader frame (3) and the steering stop on the rear frame (4) to 100 mm (4 inch).

4. Repeat Step 2 and Step 3 for the steering neutralizer screw on the right-hand side of the machine.

Check the Adjustment of the Steering Neutralizer Valve

1. Place a 25 mm (1 inch) ball of putty to the left steering stop (3) that is on the loader frame.

2. Place the transmission in neutral and start the engine.

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Illustration 581	g00769254
Level Position of Linkage Pins (A) Linkage pin (B) Linkage pin

3. Raise the empty loader bucket. The lift arm pin (A) and the bucket pin (B) should be at the same height.

4. Disengage the parking brake and the service brakes.

5. Run the engine at high idle.

6. Turn the machine all the way to the left.

7. Steer the machine so that the machine is in the straight ahead position.

8. Engage the parking brake.

9. Stop the engine.

10. Measure the thickness of the putty. The putty should not be pressed to a thickness that is less than 4 ± 1 mm (0.16 ± 0.04 inch).

11. If necessary, adjust stud assembly (1) until the dimension is correct.

12. Repeat Step 1 through Step 11 for the right steering stop.

Fast Fill Automatic Lubrication Service

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Illustration 582	g01642573
Fast Fill Automatic Lubrication Service (1) Air pressure gauge (2) Steering and brake oil (3) Radiator and aftercooler coolant (4) Engine crankcase oil (5) Oil renewal system (6) Autolube reservoir (7) Pressurized air (8) Implement hydraulic oil (9) Engine coolant (10) Brake cooling oil (11) Transmission oil

1. Open the cover for the fast fill automatic lubrication service on the right-hand side of the rear frame.

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

Commissioning Procedure

Make sure that all of the fluid levels are properly filled before the commissioning procedures begin.

Check the machine systems. Make sure that the systems are within specifications before the machine is put in service.

Make sure that the steering stops are adjusted to a 100 mm (4.0 inch) gap.

ReferenceRefer to Special Instruction, "Check the Adjustment of the Steering Neutralizer Valve" for additional information.

Articulate the machine. Grease the upper drive shaft and the lower drive shaft across the hitch.

The list that follows shows the recommended assembly checks for the machine. The list also shows the recommended system checks for the machine. Perform the checks before the machine is delivered to the customer. Mark the list "YES" when the system functions properly. Mark the list "NO" when the system malfunctions. Record the information on the pages at the rear of this manual.

Refer to the Service Manual in order to correct any system malfunction. Any system malfunction must be corrected before the machine is delivered.

The following information covers the testing procedures for the 994H Wheel Loaders.

Update VIMS Configuration of the Machine

An update of the VIMS configuration is necessary when the machine is first delivered. After the machine is assembled, connect a computer to the service port and run Electronic Technician.

1. Select the "VIMS Main Module" ECM when prompted.

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

3. Follow the instructions that are shown in Electronic Technician to update the clock on the VIMS ECM.

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

5. Under the list of configurations for the "VIMS Main Module", select "General Information".

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

7. Follow the instructions that are shown in Electronic Technician to assign the equipment number for the machine.

8. Close Electronic Technician and disconnect the computer from the machine.

Power Train

Engine

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

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

3. Engine speed at low idle should be 750 ± 310rpm.

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

5. See the engine information plate for the values.

6. Full load rpm should be 1600 ± 10 rpm.

7. Stall the torque converter.

8. Boost pressure is specified as 123 kPa (18 psi) (105 to 142 kPa (15 to 21 psi)).

9. The boost pressure can also be specified by 890 mm (35 inch) of HG (785 to 1065 mm (30.9 to 41.9 inch)).

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

11. Oil pressure should be 331 to 600 kPa (48 to 87 psi) at full load.

12. Operate the machine at the full load rpm of 1600 ± 10 rpm.

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

Torque Converter

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

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

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

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

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

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

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

7. For additional information, refer to Testing and Adjusting, RENR0751, "994H Wheel Loader Power Train".

Torque Converter Stall

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NOTICE
Do not keep the torque converter in a stall condition for long periods of time. Damage could occur in the torque converter, the engine, and the brakes.

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Illustration 583	g01176744
Pressure Tap Locations for Braking System, Steering System, and Transmission

1. Install a hose and a 1400 kPa (200 psi) pressure gauge on pressure tap "TC - OUT". Refer to Illustration 583.

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

3. Start the engine.

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

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

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

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

8. Release the parking brake.

9. Shift the transmission into SECOND SPEED FORWARD.

10. Slowly increase the engine rpm to full throttle. The machine will try to move.

    Note: Put the machine against a solid object that will not move, if the brakes will not keep the machine from moving.

11. The engine rpm should be 1610 ± 40 rpm with the torque converter in the stall condition.

12. The pressure on the gauge should be 470 ± 100 kPa (70 ± 15 psi).

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

14. Stop the engine and remove the test equipment.

Torque Converter Lockup Clutch "LUC"

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Illustration 584	g01176744
Pressure Tap Locations for Braking System, Steering System, and Transmission

1. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap "LUC". Refer to Illustration 584.

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

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

4. Start the engine.

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

6. Place the machine in SECOND SPEED FORWARD.

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

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

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

10. The maximum stabilized pressure should be 2340 ± 70 kPa (340 ± 10 psi).

Torque Converter Impeller Clutch Pressure "IC"

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Illustration 585	g01176744
Pressure Tap Locations for Braking System, Steering System, and Transmission

1. Install a hose and a 4130 kPa (600 psi) pressure gauge on pressure tap "IC". Refer to Illustration 585.

   Note: IC pressure can also be seen through Advisor.

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

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

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

5. The maximum pressure should be no lower than 1850 kPa (268 psi).

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

7. Observe the pressure reading on the gauge.

8. The default setting is 400 ± 100 kPa (58 ± 15 psi).

9. Press the reduced rimpull button on the keypad.

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

11. Repeat Steps 9 and 10 for the other reduced rimpull settings.

Transmission

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

2. Operate the engine at high idle speed.

3. The speed clutch pressure tap "P1" should be 2760 ± 140 kPa (400 ± 20 psi).

4. Operate the engine at high idle speed.

5. The direction clutch pressure "P2" should be 2170 ± 140 kPa (315 ± 20 psi).

6. Operate the engine at high idle speed.

7. The transmission lubrication pressure "LUBE" should be no less than 140 kPa (20 psi).

8. Operate the engine at low idle speed.

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

10. The differential pressure is the difference between the "P1" and "P2" values.

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

12. The torque converter inlet pressure ("TC - IN") at high idle is 900 kPa (130 psi).

13. Partially depress the left pedal.

14. The impeller clutch must slip in all gears.

15. Torque converter output should be 25% of the torque at the lockup clutch.

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

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

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

Torque Converter Inlet Pressure "TC - IN"

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Illustration 586	g01176744
Pressure Tap Locations for Braking System, Steering System, and Transmission

1. Connect a hose to pressure tap "TC - IN". Connect a 1400 kPa (200 psi) pressure gauge to the opposite end of the hose. Refer to Illustration 586.

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

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

Differential and Final Drive

Fill the oil reservoir to the proper level. Operate the machine at full throttle in first gear for a minimum of 1.5 minutes. Operate the machine in both forward and reverse directions under these conditions.

1. The oil compartments must not leak.

2. No unusual noises should be coming from the machine.

Parking Brakes and Service Brakes

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

2. Engage the parking brake.

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

4. The action lamp will be blinking red.

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

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

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

Brake Accumulator Charging Valve

1. Operate the engine at low idle speed. The accumulator pressure must increase to 15500 to 16500 kPa (2250 to 2395 psi).

2. Pump brake pedal repeatedly and check that the accumulator pressure returns to 15500 kPa (2248 psi) to 16500 kPa (2393 psi)

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

4. The actuation pressure should be 10350 kPa (1501 psi) while the right brake pedal or the left brake pedal is depressed.

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

6. Purge the brakes at each wheel.

Air System

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Illustration 587	g00773094
Bottom View of Air Tank on Right Hand Side of Platform

1. Connect a 0 to 1380 kPa (0 to 200 psi) pressure gauge.

2. Start the engine.

3. Use a 3R-4825 Control Valve in order to drain the air tank.

4. The cut-in pressure should be a minimum of 655 kPa (95 psi).

5. Stop draining the air tank.

6. The pressure for the cutout should be 828 ± 34 kPa (120 ± 5 psi).

Tires

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

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

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

Hydraulics

Steering Check

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NOTICE
Purge the air in the cylinders by slowly stroking the cylinders ten times in both directions. If the cylinders have not been purged of air, do not bottom out the rod stroke at either end. Air in the cylinders can damage the cylinder seals.

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Illustration 588	g01176744
Pressure Tap Locations for Braking System, Steering System, and Transmission

1. Operate the engine at high idle speed.

2. The pilot pressure should be 3450 ± 350 kPa (500 ± 70 psi) when the STIC is not active.

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

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

5. Separate the steering frame lock in order to steer the machine.

6. Stall the steering against the right or left stop. Steering pressure should be 29000 ± 750 kPa (4206 ± 109 psi)

7. The turning time between the right turn stop and the left turn stop should be 4.1 to 4.5 seconds.

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

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

10. The time must not vary more than 0.3 seconds from the time in Step 7.

11. Adjust the neutralizer stems so that there is a 100 mm (4.0 inch) gap between the stops of the frame at a full left turn or a full right turn. Refer to Special Instruction, "Adjust the Steering Neutralizer Valve" for more information.

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

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

14. The machine should not articulate more than 3 degrees after the STIC returns to the NEUTRAL position.

Supplemental Steering

1. Operate the machine in an open area at the maximum forward ground speed.

2. Shift the transmission into NEUTRAL.

3. Stop the engine.

The machine should be easy to steer. The machine should respond in a similar manner as an operating machine. The steering response will decrease as the machine slows to a stop.

Electrohydraulic

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

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

2. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Service". Press the "OK" button.

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

4. The Advisor module may ask for a password. Enter the password. Press the "OK" button in order to continue.

   Note: The default password is "0"

5. Select "Lever Sensors" from the "Implement" menu. Press the "OK" button.

6. Select "Lift Lever Cal" from the "Lever Sensors" menu and press the "OK" button in order to begin the calibration of the lift lever sensor.

7. Follow the instructions that are shown on the Advisor display in order to perform the calibration.

8. Repeat Steps 2 through 8 in order to calibrate the tilt lever sensor. Select "Tilt Lever Cal" in Step 7 in order to perform this calibration.

9. Repeat Steps 2 through 8 in order to calibrate the lift linkage sensor. Select "Linkage Sensors" complete in Step 6, then "Lift Sensor Cal" in Step 7 in order to perform this calibration.

10. Repeat Steps 2 through 8 in order to calibrate the tilt linkage sensor. Select "Linkage Sensors" in Step 6, then "Tilt Sensor Cal" in Step 7 in order to perform this calibration.

11. Repeat Steps 2 through 8 in order to calibrate the center pump solenoid. Select "Pumps" in Step 6, then "Center Pump Cal" in Step 7 in order to perform this calibration.

12. Repeat Steps 2 through 8 in order to calibrate the left front pump solenoid. Select "Pumps" in Step 6, then "Left Front Pump Cal" in Step 7 in order to perform this calibration.

13. Repeat Steps 2 through 8 in order to calibrate the left rear pump solenoid. Select "Pumps" in Step 6, then "Left Rear Pump Cal" in Step 7 in order to perform this calibration.

14. Repeat Steps 2 through 8 in order to calibrate the right pump solenoid. Select "Pumps" in Step 6, then "Right Pump Cal" in Step 7 in order to perform this calibration.

15. Repeat Steps 2 through 8 in order to calibrate the raise valve solenoids. Select "Implement Valves" in Step 6, then "Raise Valve Cal" in Step 7 in order to perform this calibration.

16. Repeat Steps 2 through 8 in order to calibrate the lower valve solenoids. Select "Implement Valves" in Step 6, then "Lower Valve Cal" in Step 7 in order to perform this calibration.

17. Repeat Steps 2 through 8 in order to calibrate the rack valve solenoids. Select "Implement Valves" in Step 6, then "Rack Valve Cal" in Step 7 in order to perform this calibration.

18. Repeat Steps 2 through 8 in order to calibrate the dump valve solenoids. Select "Implement Valves" in Step 6, then "Dump Valve Cal" in Step 7 in order to perform this calibration.

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

20. The loader bucket must be empty.

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

22. The lift and tilt function should operate properly.

23. Operate the engine at high idle speed.

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

25. The lift and tilt cylinders must not move.

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

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

Implement

1. Start the engine.

   Note: The oil temperature should be 52° C (125° F) at high idle speed

2. Connect a Communications Adaptor to the machine service port in the cab. Start Electronic Technician on the computer.

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

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

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

6. Follow the Electronic Technician procedures. Ensure that all four main relief tests are selected when prompted.

7. Each main relief pressure pressures should read 32800 ± 400 kPa (4760 ± 60 psi).

8. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Service". Press the "OK" button.

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

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

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

12. Follow the instructions that are shown on the Advisor display. The lift times should be 11-12 seconds (SL or HL), 13-14 seconds (EHL or SHL).

13. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Service". Press the "OK" button.

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

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

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

17. Follow the instructions that are shown on the Advisor display.

18. Repeat Steps 15 through 19 in order to run the tilt cylinder drift check. Select "Tilt Cylinder" in Step 18 in order to run this test.

19. The allowable drift rates are dependent on oil temperature and run over a 5 minute period. See the following table for additional information.

Table 99

Hydraulic Oil Temp	Lift Drift	Tilt Drift
40° - 49°C	5 mm (0.2 inch)	2 mm (0.07 inch)
50° - 59°C	7 mm (0.3 inch)	3 mm (0.11 inch)
60° - 69°C	10 mm (0.4 inch)	4 mm (0.16 inch)

Leakage

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

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

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

4. Inspect all lines, connections, fittings, and cylinder rod seals for leaks.

   Note: Do not hold the relief valve pressure for more than 10 seconds when the cylinders reach the end of the stroke. If more time is needed to conduct the test, do not increase the pressure for at least 1 minute.

Operator Module

Steering Control

1. Operate the engine at high idle speed. Move the stick to the right. The machine must articulate to the right.

2. Operate the engine at high idle speed. Move the stick to the left. The machine must articulate to the left.

Transmission Control

1. Move the transmission control switches through all of the possible combinations. Ensure that the proper transmission indicator lamp is on.

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Illustration 589	g02688703
Reduced Rimpull Button (1) on Right Hand Side of Console

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

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

Parking Brake Control

1. Pull the parking brake knob outward in order to engage the parking brake.

   Note: The parking brake knob is black and the knob is located below the dash.

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

3. Return the transmission to NEUTRAL.

4. Select 2nd or 3rd gear and engage the transmission in either direction. The transmission should engage and the alert indicators will be blinking red. A "Parking Brake On" message should appear on the Advisor module.

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

6. Return the transmission to NEUTRAL.

7. Push the parking brake knob inward in order to release the parking brake.

8. If the parking brake knob does not stay down, the brake system pressure of the machine is not high enough to disengage the parking brake.

   Note: Do not move the machine until the problem is corrected.

Throttle Control

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

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

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

4. Release the pedal.

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

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

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

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

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

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

Brake Pedals

1. Depressing the right brake pedal must apply brakes at all four wheels.

2. Depressing the right brake pedal must cause the brake lights at the rear of the machine to turn on.

Left Pedal Control

1. Partially depressing the left pedal must allow the impeller clutch to slip.

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

3. The torque should be 25% of the output torque when the lockup clutch is enabled.

4. Depress the left pedal further.

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

6. Apply the brakes at all four wheels.

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

Seat Controls

Check the following adjustments:

• Seat travel: 150 mm (5.9 inch) total

• Seat height: 75 mm (3 inch) total

• Seat suspension: adjustable

• The seat cushion is adjustable: two positions

• The back seat cushion is adjustable: three positions

Seat Belt

1. Adjust the seat belt to the proper length.

2. Latch the seat belt across the lap of the operator. The length of the seat belt must not change. The seat belt must not slip on the operator.

3. Release the seat belt. The seat belt must unlatch.

Electrohydraulic Controls for Loader Bucket

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

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

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

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

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

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

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

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

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

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

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

12. Control the bucket down to the lower position.

Instrument Panel

1. Turn the engine start switch key to the ON position. Power is now supplied to all of the electrical circuits in the cab. Some functions can be checked with the key in the ON position such as the dome lights and the window wiper blades.

2. Turn the engine start switch key to the START position. The diesel engine will start. Release the engine start switch key after the engine starts. The engine start switch key must return to the ON position.

3. Turn the engine start switch key to the OFF position. The engine must stop. The electrical circuits in the cab must go to the de-energized state. The following components should have electrical power:
   • Instrument Panel Lights

   • Running Lights on the Front of the Machine

   • Tail Lights

   • Flood Lamps for the Access Ladder.

Climate Control

1. Cab Pressurization

   With the engine stopped, turn the start dial key to the ON position. Turn the blower fan dial to the LOW position. Then, turn the blower fan dial to the HIGH position. A normal sound must be heard at both fan speeds.

2. Heating

   The engine must be running at normal operating temperature and the valves for the heater lines must be open. Press the A/C Control Switch to "Heat" position. Turn the temperature dial toward the "Hot" region.

3. Air Flow

   Turn the blower fan dial to the LOW position or the HIGH position. There must be air flow at the dash assembly under the front window wiper blades. There must be air flow on both sides of the seat support.

Heated Mirrors (If Equipped)

1. Depress the heated mirrors button on the keypad. Confirm that the mirrors are heated in 5 minutes.

Backlight Dimmer

1. Depress the backlight dimmer button on the keypad. Confirm that the LEDs, keypad buttons, Advisor module, and Gauge Cluster are dimmed then previously.

2. Continue to depress the backlight dimmer on the keypad until the LEDs, keypad buttons, Advisor module, and Gauge Cluster are at fully lit.

Manual Autolube

1. Depress the manual lube button. Confirm that the Autolube system is running and completes a cycle without an Autolube event being issued in Electronic Technician or in the Advisor module.

Window Wiper Blades

1. The ignition switch must be in the ON position. Turn the wiper switches to the LOW position and the HIGH position. The wiper arms for both the front and the rear must operate in both modes.

2. Depress the wiper switch knobs in order to operate the washers.

3. Turn the switches to the OFF position. The wiper arms for both the front and the rear must return to the proper OFF position.

Running Lights

1. The ignition switch must be in the OFF position. Push the three-position switch to the middle position. The instrument panel lights and the tail lights must be ON.

2. Push the three-position switch to the UP position. The running lights must also turn ON.

Flood Lamps

The ignition switch must be in the ON position. Push the switch for the flood lamps to the ON position. Check the flood lamps. The flood lamps must turn ON.

Auxiliary Flood Lamps

1. The ignition switch must be in the OFF position. Push the switch for the lamps at the access ladders to the ON position. The lamps in the engine compartment must turn ON.

2. Push the switch to the ON position for the lamps in the engine compartment. The switch is located at the ground level in the bumper assembly. The lamps in the engine compartment must turn ON.

Dome Lights

The ignition switch must be in the OFF position. Depress the dome light switch. The dome light must turn ON.

Lighter

The ignition switch must be in the ON position. Depress the lighter to the detent position. The lighter must pop out of the detent position when the lighter is ready for use.

Machine Horns

The ignition switch must be in the OFF position. Press the horn switch on the floor. The horns must sound.

Machine Operation

Note: Operate the machine for 10 hours in first gear or second gear. DO NOT operate the machine in third gear during the break-in period.

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

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

2. Any indication of improper operation must be corrected. Improper operation can include harsh braking, jerky steering, unusual noises, or improper linkage movements.

Final Testing of Wheel Loader

Check the complete machine. There should be no unusual noises or oil leaks. All of the quality requirements must be fulfilled. Machine function and appearance must meet specifications. All variances must be recorded, and the variances must be corrected.

Perform Payload Calibration

1. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Payload". Press the "OK" button.

2. Select "Advanced Configuration" from the "Payload" menu. Press the "OK" button.

3. Select "Calibrate Payload" from the "Advanced Configuration" menu. Press the "OK" button.

4. The Advisor module may ask for a password. Enter the password. Press the "OK" button in order to continue.

   Note: The default password is "0"

5. Select "Empty Bucket Lift" from the "Calibrate Payload". Press the "OK" button to begin the empty bucket calibration.

6. Follow the instructions that are shown on the Advisor display in order to run the calibration.

7. Repeat Steps 1 through 6 in order to calibrate with a known weight in the bucket. Select "Full Bucket Lift" in Step 5 in order to perform this calibration.

8. Repeat Steps 1 through 6 in order to calibrate with a known weight in the bucket at different lift speeds. Select "Full Bucket Velocity" in Step 5 in order to perform this calibration.

9. Repeat Steps 1 through 4 in order to enter the known weight in Step 7 and 8 used for payload calibration. Select "Calibration Weight" in Step 3 in order to enter the calibration weight.

Target Weight for the Loader Bucket

Note: System Operations, UENR2455, "994H Large Wheel Loader Payload Control system (PCS)" for more information.

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

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

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

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

1. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Payload". Press the "OK" button.

2. Select "Advanced Configuration" from the "Payload" menu. Press the "OK" button.

3. Select "Ldr Bucket Trgt Wt" from the "Advanced Configuration" menu. Press the "OK" button.

4. The Advisor module may ask for a password. Enter the password. Press the "OK" button in order to continue.

   Note: The default password is "0"

5. Follow the instructions that are shown on the Advisor display in order to enter the target bucket weight.

Configure Payload Control System

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

1. Press the "HOME" button on the Advisor module in order to bring up the "HOME" menu. Select "Payload". Press the "OK" button.

2. Select "Basic Configuration" from the "Payload" menu. Press the "OK" button.

3. Select "Payload Indicator Config" from the "Basic Configuration" menu. Press the "OK" button.

4. Refer to "DISPLAY MODE" from the information form to select the desired configuration.

5. Repeat Steps 2 through 4 to set the weigh activation and range parameters. Select "Set Weigh Range" in Step 3. Refer to "PAYLOAD WEIGH ACTIVATION LIFT POSITION" and "PAYLOAD WEIGH RANGE CONFIGURATION" in Step 4 to configure the weigh activation height and range parameters.

6. Select "Advanced Config" from the "Payload" menu. Press the "OK" button.

7. Select "Auto Truck ID" from the "Advanced Config" menu. Press the "OK" button.

8. Refer to "AUTO TRUCK ID ENABLE" from the information form to select the desired configuration.

9. Repeat Steps 5 through 7 to set the configuration for the Auto Material ID feature. Select "Auto Material ID" in Step 7 and refer to "AUTO MATERIAL ID ENABLE" in Step 8 in order to select the desired configuration.

10. Repeat Steps 5 through 7 to set the configuration for the Payload Horn feature. Select "Payload Horn" in Step 7 and refer to "STORE PAYLOAD DATA HORN CONFIGURATION" in Step 8 to select the desired configuration.

11. Repeat Steps 5 through 7 to set the configuration for the Payload Overload Warning feature. Select "PL Overload Warning" in Step 7 and refer to "PAYLOAD OVERLOAD WARNING ENABLE" in Step 8 to set the desired configuration.

12. Repeat Steps 5 through 7 to set the configuration for the Payload Lift Cylinder Maximum Velocity parameter. Select "Max Vel Cnf" in Step 7 and refer to "PAYLOAD LIFT CYLINDER MAXIMUM VELOCITY CONFIGURATION" in Step 8 to set the desired configuration.

13. Repeat Steps 5 through 7 to set the configuration for the Payload Lift Speed Skew Limit Configuration parameter. Select "Lft Spd Skw Lmt Cnf" in Step 7 and refer to "PAYLOAD LIFT SPEED SKEW LIMIT CONFIGURATION" in Step 8 to set the desired configuration.

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

15. Click the "Connect" button to establish communication with the VIMS Main Module ECM.

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

17. Click on "PCS" at the top of the webpage.

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

19. Repeat Step 18 and select "LoadsiteID".

20. Repeat Step 18 and select "DelayCodes".

21. Repeat Step 18 and select "TruckID".

Illustration 590	g02627178

Illustration 591	g02627180

Illustration 592	g02627181

Illustration 593	g02627182

Illustration 594	g02627183

Note: Refer to Systems Operation, UENR2455, "Payload System" for more information about the configuration parameters.

Activate Product Link

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

Checks Before Delivery of 994H Wheel Loader

The following list shows the recommended assembly checks and the system checks for the machine. Perform the checks before the machine is delivered to the customer. Do all the checks and verify that all the systems function properly.

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

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

Make copies, and mail to the address provided.

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

Dealer____________________

Customer____________________

Product Identification Number____________________

1. Check to make sure that all of the hydraulic systems are full and the implement pump case drains are full prior to starting the engine. YES_____ NO_____

2. Check the system pressure settings for the correct specifications.
   • Implement
     YES_____ NO_____

   • Pilot system
     YES_____ NO_____

   • Brake
     YES_____ NO_____

   • Steering
     YES_____ NO_____

   • Transmission
     YES_____ NO_____

   • Torque Converter
     YES_____ NO_____

3. Were the machine lights checked?
   • Operational
     YES_____ NO_____

   • Ladder light
     YES_____ NO_____

   • Cab
     YES_____ NO_____

   • Dash
     YES_____ NO_____

   • Engine compartment
     YES_____ NO_____

4. Cab:
   • Cab door opens and close from the inside of the cab? YES_____ NO_____

   • Is the Operation and Maintenance Manual in the literature pouch? The literature pouch is located on the back side of the operator seat.YES_____ NO_____

   • Does the horn function correctly? YES_____ NO_____

   • Does the window wiper/washer function correctly?
     YES_____ NO_____

   • Do the seat belts function correctly?
     YES_____ NO_____

   • Does the fan switch function correctly?
     YES_____ NO_____

   • Does the heater function correctly?
     YES_____ NO_____

   • Does the air conditioner function correctly?
     YES_____ NO_____

   • Check the EMS or VIMS test. Does the check light function correctly?
     YES_____ NO_____

   • Does the hour meter function correctly?
     YES_____ NO_____

   • Does the dead engine lower function correctly?
     YES_____ NO_____
     

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

   • Does the throttle controls function correctly?
     YES_____ NO_____
     

   • Does the automatic engine speed control function correctly?
     YES_____ NO_____

   • Does the steering column function correctly?
     YES_____ NO_____

   • Does the parking brake function correctly?
     YES_____ NO_____

5. Was the automatic ether injection system checked? Refer to Operation and Maintenance Manual, SEBU7885, "994H Wheel Loader" for the correct procedure.
   YES_____ NO_____

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

7. Were all the fluid levels rechecked?
   YES_____ NO_____

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

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

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

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

12. Was the backup alarm function checked? YES_____ NO_____

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

14. Was there any damage during shipment?
    YES_____ NO_____

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

16. Name of the person making the checks:
    • Hydraulic____________________

    • Electrical____________________

    • Structural____________________

    • Other____________________

17. Comments:

    a.____________________

    b.____________________

    c.____________________

    d.____________________

    e.____________________

    f.____________________

    g.____________________

    h.____________________

    i.____________________

    j.____________________

    k.____________________

    l.____________________

    m.____________________

    n.____________________

    o.____________________

    p.____________________

    q.____________________

    r.____________________

    s.____________________

    t.____________________

Table 100

Specifications
Description	Condition	Specification	Actual	Comment
Power Train
Engine RPM	High Idle	1700 ± 10 rpm
Engine RPM	Low Idle	750 ± 10 rpm
Boost Pressure	Torque Converter Stall	minimum of 105 kPa (15 psi) maximum of 140 kPa (20 psi)
Oil Pressure	Low Idle	minimum of 140 kPa (20 psi)
Oil pressure	Full Load	minimum of 275 kPa (40 psi)
Fuel Pressure	1000 rpm and Full Load	415 kPa (60 psi) to 450 kPa (65 psi)
Torque Converter
Engine Rpm	Torque Converter Stall	minimum of 1610 ± 40 rpm
Torque Converter Outlet	-	470 ± 100 kPa (68 ± 15 psi)
Torque Converter Lockup Clutch	-	2340 ± 70 kPa (340 ± 10 psi)
Torque Converter Impeller Clutch	High Idle, Pedal Released	1850 ± 105 kPa (270 ± 15 psi)
Torque Converter Inlet Pressure	High Idle	900 kPa (130 psi)
Transmission
P1 Speed Clutch Pressure	High Idle	2760 ± 140 kPa (400 ± 20 psi)
P2 Direction Clutch Pressure	High Idle	2170 ± 140 kPa (400 ± 20 psi)
Transmission Lubrication Pressure	High Idle	minimum of 140 kPa (20 psi)
Transmission Lubrication Pressure	Low Idle	minimum of 7 kPa (1 psi)
P1-P2 Differential Pressure	High Idle	590 ± 35 kPa (85 ± 5 psi)
	Partially depress the left pedal.	Torque converter output should be 25% of the torque at the lockup clutch.
	Shift the transmission.	The transmission shifts smoothly in all gears.
Parking and Service Brakes
Brake System Pressure	The pressure is below 6900 kPa (1000 psi).	The alert indicator for the parking brake must be red.
	With the parking brake engaged, shift the transmission to any gear except neutral.	The alarm on the instrument panel must sound intermittently and the respective gear indicator must turn on.
Brake System Pressure in the normal range	Engage the parking brake.	The alert indicator for the parking brake must be red.
Brake System Pressure at maximum brake pedal travel	High Idle	10340 ± 345 kPa (1500 ± 50 psi)
Accumulator Precharge	Accumulator precharge	5520 ± 280 kPa (800 ± 40 psi)
Charge Pump for the Brake Accumulator	Accumulator pressure at low idle	15500 to 16500 kPa (2250 to 2390 psi)
Air System
	Cut in pressure	655 kPa (95 psi)
	Cut out pressure	830 ± 35 kPa (120 ± 5 psi)
Tires
	Tire pressure	Use the recommendations of the manufacturer.
Hydraulics
Steering System	Standby pressure for the primary steering pump	3755 ± 1240 kPa (545 ± 180 psi)
	Steering Pressure at Relief	29000 ± 750 kPa (4206 ± 109 psi)
	Turning time between the left turn stop and the right turn stop	4.1 to 4.5 seconds
	Difference between steering left and steering right	0.3 seconds max
	Gap between the stops of the frame at a full left turn or a full right turn	100 mm (4 inch)
	Articulate the machine for 3 degrees and measure the amount of travel after stopping the STIC movement.
Pilot Pressure	Low idle	345 ± 35 kPa (500 ± 70 psi)
Implement Standby pressure should be 2500 ± 100 kPa (362 ± 14 psi)	High idle Loader bucket at full tilt Main relief pressure for the implement system	32800 ± 400 kPa (4760 ± 60 psi)
	Implement oil temperature	52 °C (125 °F)
	High idle Transmission in neutral Measure the time that is required to raise the empty loader bucket from the ground to the end of the lift cycle.	11 - 12 seconds 13-14 seconds for EHL, SHL
	High idle Raise the loader bucket until the lift cylinders are fully extended. Measure the time that is required to move the loader bucket to the dump stop from the full tilt back position.	11 -12 seconds 13-14 seconds for EHL, SHL
Lift Cylinder	Raise the loader bucket until the lift cylinders are fully extended. Measure the lift cylinder rod drift.	35 mm (1.38 inch) max in 5 minutes 50-59°C
Tilt Cylinder	Raise the loader bucket until the lift cylinders are fully extended and the loader bucket is level. Measure the tilt cylinder rod drift.	14 mm (0.55 inch) max in 5 minutes 50-59°C
Leakage		None
Operators Module
Steering Control	Move the STIC to the right.	The machine must articulate to the right.
	Move the STIC to the left.	The machine must articulate to the left.
Transmission Control	Move the transmission control switch through all of the different gear positions.	The respective indicator lamp for each gear must come on.
	Depress the reduced rimpull button.	The indicator lamp for the rimpull must be on and LED's above the reduced rimpull switch will be lit according to rimpull settings.
	Depress the lockup clutch switch.	The indicator lamp must turn on.
Parking Brake Control	Engage the parking brake by pulling the brake knob	Parking brake indicator must be lit
	With the parking brake ON, shift into a 1st gear with the transmission switch	Transmission must not engage.
	Return the transmission to NEUTRAL, and shift into a 2nd or 3rd gear.	Transmission must engage and the alert indicators must be lit.
	Push the red brake knob downward.	The knob must stay down.
Throttle Control	The engine must be running. Push the throttle lock enable switch to the ON position.	The throttle lock lamp must turn on.
	Enable the throttle lock. Depress the accelerator pedal all the way to the stop.	The engine must be running at high idle.
	Release the accelerator pedal.	The pedal must automatically return to the low idle position.
	Depress the accelerator pedal and press the throttle lock enable switch. Release the accelerator pedal.	The engine speed must be held at the same rpm.
	The engine speed must be held by the throttle lock and the accelerator pedal must be released. Press the brake pedal.	The engine speed must return to low idle.
	Press the resume switch for the throttle.	The engine speed must increase, and the engine speed must return to the previously set rpm.
Brake Pedal	Depress the brake pedal.	Applies the brakes to all four wheels. The brake lights at the rear of the machine must turn on.
Left Pedal Control	Partially depress the left brake pedal.	Will reduce the output torque of the torque converter. The torque should be 25% of the lockup torque converter.
	Fully depress the left brake pedal.	Will apply the brakes to all four wheels. The brake lights at the rear of the machine must turn on.
Seat Adjustment Lever	Travel	150 mm (6 inch)
	Height	75 mm (3 inch)
	Suspension	Adjustable
	Back Cushion	Three positions
Seat Belt	Adjust the seat belt to the proper length. Fasten the seat belt.	The seat belt must not slip and the seat belt must not change length.
	Release the seat belt.	The seat belt must unlatch.
Implement Controls	Pull the lift lever rearward past the soft detent and release the lift lever	Bucket must stop smoothly at raise kickout position.
	Push the lift lever forward past the soft detent and release the lift lever	Bucket must stop smoothly at lower kickout position.
	Pull the tilt lever rearward past the soft detent and release the tilt lever	Bucket must stop smoothly at rack kickout position.
	With the bucket near the ground, push the lift lever forward past the soft detent and release the lift lever	Bucket must float down to the ground and float icon will be lit.
Instrument Panel	Turn the key to the ON position.	VIMS does a self test. The gauges will travel through the entire range of motion.
	Turn the ignition switch and hold the switch in the START position.	The diesel engine must start.
	Release the ignition switch after the engine starts.	The key must return to the ON position.
	Turn the ignition switch to the OFF position.	The engine must stop. All the electrical circuits must de-energize except the instrument panel lights, the running lights, the tail lights, and the lights for the access ladders.
Climate Control	The engine must be stopped and the ignition switch must be ON. Turn the fan speed control dial to the LOW position and the HIGH position.	The fan must be audible at both speeds.
	The engine must be running at normal operating temperature and the valves for the heater lines must be open. Turn the heater control switch ON.	There must be warm air at the dash assembly under the front window wiper blades. There must be warm air on both sides of the seat support.
	Turn the fan speed control dial to the LOW position or the HIGH position.	There must be air flow at the dash assembly under the front window wiper blades. There must be air flow on both sides of the seat support.
Window Wiper Blades	The ignition switch must be in the ON position. Turn the wiper switches to the LOW position and the HIGH position.	The wiper arms for both the front and the rear must operate in both modes.
	Depress the wiper switch knobs.	The washers must operate.
	Turn the switches to the OFF position.	The wiper arms for both the front and the rear must return to the proper OFF position.
Running Lights	The ignition switch must be in the OFF position. Push the three-position switch to the middle position.	The instrument panel lights and the tail lights must be ON.
	Push the three-position switch to the UP position.	The running lights must also turn ON.
Flood Lamps	The ignition switch must be in the ON position. Push the switch for the flood lamps to the ON position.	All of the flood lamps must be ON.
Auxiliary Flood Lamps	The ignition switch must be in the OFF position. Push the switch for the lamps at the access ladders to the ON position.	The lamps in the engine compartment must turn ON.
	Push the switch to the ON position for the lamps in the engine compartment. The switch is located at the ground level in the bumper assembly.	The lamps for the engine compartment must turn ON.
Dome Lights	The ignition switch must be in the OFF position. Depress the dome light switch.	The dome light must turn ON.
Lighter	The ignition switch must be in the ON position. Depress the lighter to the detent position.	The lighter must pop out of the detent position when the lighter is ready for use.
Machine Horns	The ignition switch must be in the OFF position. Press the horn switch on the floor.	The horns must sound.
Heated Mirrors	Press the heated mirrors button	Mirrors should be heated in 5 minutes
Backlight Dimmer	Press the backlight dimmer button	Keypad button and displays should dim through four settings
Manual Lube	Press the manual lube button	Manual lube cycle should be initiated and no warnings should appear