994H Wheel Loader Power Train Caterpillar

Assembly Procedure

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Illustration 1	g00577360

1. Position the case assembly (1) , as shown. Support the case assembly (1) with suitable cribbing, as shown. The weight of the case assembly (1) is 1114 kg (2455 lb).

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Illustration 2	g00575394

2. Lower the temperature of roller bearing cups (93) to -46° ± 6°C (-50° ± 10°F). Use Tooling (A) (not shown) in order to install one of the two roller bearing cups (93) in the gear (87) . Allow temperature of the first roller bearing cup (93) to stabilize. Install spacer ring (92) in gear (87) . Allow temperature of the second roller bearing cup (93) to stabilize. Use Tooling (A) (not shown) to seat the second roller bearing cup (93) in gear (87) .

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Illustration 3	g00575391

3. Install roller bearing cone (91) in gear (87) .

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Illustration 4	g00575389

4. Install cone spacer (90) in gear (87) .

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Illustration 5	g00575387

5. Install roller bearing cone (89) in gear (87) .

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Illustration 6	g00575386

6. Slide gear (87) on rib (88) in order to install gear (87) in case assembly (1) .

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Illustration 7	g00576136

7. Install O-ring seal (86) on idler shaft (84) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (86) .

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Illustration 8	g00615523

8. Attach Tooling (B) or 4C-8358 Eyebolt to idler shaft (84) . Position a suitable lifting device to Tooling (B) . Secure the suitable lifting device to a suitable hoist. Position idler shaft (84) to case assembly (1) . Remove Tooling (B) from idler shaft (84) .

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Illustration 9	g00575382

9. Install bolt (85) through idler shaft (84) . Tighten bolt (85) in order to draw idler shaft (84) in case assembly (1) .

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Illustration 10	g00575381

10. Lower temperature of roller bearing cup (83) to -46° ± 6°C (-50° ± 10°F). Allow temperature of roller bearing cup (83) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (83) in case assembly (1) .

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Illustration 11	g00576579

11. Raise temperature of roller bearing cone (82) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (82) on output shaft assembly (79) . Allow temperature of roller bearing cone (82) to stabilize. Use a brass drift to seat roller bearing cone (82) on output shaft assembly (79) .

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Illustration 12	g00575378

12. Install gear (81) on output shaft assembly (79) . Raise temperature of roller bearing cone (80) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (80) on output shaft assembly (79) . Allow temperature of roller bearing cone (80) to stabilize. Use a brass drift to seat roller bearing cone (80) on output shaft assembly (79) .

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Illustration 13	g00575377

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Illustration 14	g00577361

13. Attach Tooling (B) or 4C-8358 Eyebolts to output shaft assembly (79) . Position a suitable lifting device to Tooling (B) . Secure the suitable lifting device to a hoist. Install output shaft assembly (79) in case assembly (1) . The weight of output shaft assembly (79) is approximately44 kg (99 lb). Remove Tooling (B) from output shaft assembly (79) .

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Illustration 15	g00575352

14. Use Tooling (A) (not shown) in order to install lip seal (75) in bearing cage (73) . Lubricate the bore of lip seal (75) with a minimal amount of the lubricant which is being sealed.

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Illustration 16	g00575374

15. Lower the temperature of roller bearing cup (76) to -46° ± 6°C (-50° ± 10°F). Allow temperature of roller bearing cup (76) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (76) in bearing cage (73) .

    Note: Make sure that O-ring seal (77) is not installed on bearing cage (73) at this time.

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Illustration 17	g00577362

16. Tooling (C) must be modified in order to be used as guide bolts. Position Tooling (C) in a suitable vise. Remove the heads of the bolts in order to use Tooling (C) as guide bolts. Install Tooling (C) in case assembly (1) , as shown.

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Illustration 18	g00577363

17. Install bearing cage (73) , as shown. Remove Tooling (C) .

18. Use the following procedure in order to seat the bearings:
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    Illustration 19	g00577364

    1. Install four bolts (74) in bearing cage (73) , as shown. Tighten four bolts (74) to 34 N·m (25 lb ft). Torque the bolts in an alternating sequence until all the bolts are at a torque of 34 N·m (25 lb ft).
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    Illustration 20	g00615664

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    Illustration 21	g00577365

    2. Install Tooling (D) , as shown. Use a pry bar in order to rotate input shaft assembly (79) by three revolutions.

    3. Repeat Step 18.a and Step 18.b until the torque stabilizes.
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    Illustration 22	g00604264

    4. Torque four bolts (74) in an alternating sequence and repeat until all of the bolts (74) stabilize at 68 N·m (50 lb ft).
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    Illustration 23	g00577365

    5. Use a pry bar in order to rotate output shaft assembly (79) by three revolutions.

    6. Repeat Step 18.d and Step 18.e until the torque stabilizes at 68 N·m (50 lb ft).

    7. Loosen four bolts (74) . Use a pry bar in order to rotate the output shaft assembly (79) . This will ensure end play. Loosen four bolts (74) .
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    Illustration 24	g00577364

    8. Tighten four bolts (74) to 3.4 N·m (30 lb in). Alternate between opposite bolts.
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    Illustration 25	g00615664

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    Illustration 26	g00577365

    9. Install Tooling (D) , as shown. Use a pry bar in order to rotate input shaft assembly (79) by three revolutions.

    10. Repeat Step 18.h and Step 18.i until the torque stabilizes.
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    Illustration 27	g00702046
    Typical example.

    11. Mark two points on opposite sides of the bearing cage. The marks are illustrated above.
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    Illustration 28	g00702049
    Typical example.

    12. Use a standard feeler gauge to measure the gap between the bearing cage and housing assembly (1) at the two marked points. Average the two measurements.

    13. Add 0.28 mm (0.011 inch) to the average measurements that was found in step 18.l in order to achieve the shim pack thickness.
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    Illustration 29	g00577364

    14. Remove bolts (74) .

    15. Remove bearing cage (73) .
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    Illustration 30	g00577369

    16. Add the average thickness from Step 18.n with 0.28 mm (0.011 inch). This is the thickness of the shims that should be installed. Install Tooling (C) . Install shims (78) .

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Illustration 31	g00575374

19. Install O-ring seal (77) on bearing cage (73) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (77) .

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Illustration 32	g00577363

20. Install bearing cage (73) , as shown. Remove Tooling (C) .

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Illustration 33	g00577370

21. Install six bolts (74) and washers in bearing cage (73) .

22. Measure the end play for the output shafts. The end play should be 0.12 ± 0.07 mm (0.005 ± 0.003 inch).

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Illustration 34	g00575343

23. Lower the temperature of roller bearing cups (71) to -46° ± 6°C (-50° ± 10°F). Install one of the two roller bearing cups (71) in the gear (65) . Allow temperature of the first roller bearing cup (71) to stabilize. Install spacer ring (70) in gear (65) . Install the second roller bearing cup (71) in gear (65) . Allow temperature of the second roller bearing cup (80) to stabilize. Use Tooling (A) (not shown) in order to seat the second roller bearing cup (71) in gear (65) .

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Illustration 35	g00575342

24. Install roller bearing cone (69) in gear (65) .

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Illustration 36	g00575341

25. Install cone spacer (68) in gear (65) .

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Illustration 37	g00575339

26. Install roller bearing cone (67) in gear (65) .

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Illustration 38	g00575338

27. Slide gear (65) on rib (66) in order to install gear (65) in case assembly (1) .

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Illustration 39	g00575337

28. Install O-ring seal (64) on idler shaft (63) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (64) .

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Illustration 40	g00615536

29. Attach Tooling (B) or 4C-8358 Eyebolt to idler shaft (63) . Position a suitable lifting device to Tooling (B) . Secure the suitable lifting device to a suitable hoist. Position idler shaft (63) to case assembly (1) . Remove Tooling (B) from idler shaft (63) .

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Illustration 41	g00575333

30. Install bolt (62) through idler shaft (63) . Tighten bolt (62) in order to draw idler shaft (63) in case assembly (1) .

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Illustration 42	g00575312

31. Lower temperature of roller bearing cup (61) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (61) in case assembly (1) . Allow temperature of roller bearing cup (61) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (61) in case assembly (1) .

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Illustration 43	g00577393

32. Raise temperature of roller bearing cones (59) and (60) to 135° ± 14°C (275° ± 25°F). Install roller bearing cones (59) and (60) on gear (58) . Allow temperature of roller bearing cones (59) and (60) to stabilize. Use a brass drift to seat roller bearing cones (59) and (60) on gear (58) .

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Illustration 44	g00575306

33. Use two people in order to install gear (58) in case assembly (1) . The weight of gear (58) is approximately 44 kg (98 lb).

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Illustration 45	g00577397

34. Lower temperature of roller bearing cup (56) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (56) in bearing cage (55) . Allow temperature of roller bearing cup (56) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (56) in bearing cage (55) .

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Illustration 46	g00577399

35. Install bearing cage (55) , as shown.

36. Use the following procedure in order to seat the bearings:
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    Illustration 47	g00577400

    1. Install four bolts (54) in bearing cage (55) , as shown. Tighten four bolts (54) to 34 N·m (25 lb ft). Torque bolts (54) in an alternating sequence until all of the bolts are at the torque of 34 N·m (25 lb ft).
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    Illustration 48	g00615720

    2. Use a pry bar in order to rotate the output shaft assembly (79) at least one revolution.

    3. Repeat Step 36.a and Step 36.b until the torque stabilizes.
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    Illustration 49	g00615541

    4. Torque the four bolts (54) in an alternating sequence and repeat until all bolts (54) stabilize at 68 N·m (50 lb ft).
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    Illustration 50	g00577365

    5. Use a pry bar in order to rotate output shaft assembly (79) by three revolutions.

    6. Repeat Step 36.c and Step 36.e until the torque stabilizes at 68 N·m (50 lb ft). Loosen four bolts (54) .
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    Illustration 51	g00577400

    7. Tighten four bolts (54) to 3.4 N·m (30 lb in). Alternate between opposite bolts.
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    Illustration 52	g00615720

    8. Use a pry bar in order to rotate the output shaft assembly (79) at least one revolution.

    9. Repeat Step 36.g and Step 36.h until the torque stabilizes.
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    Illustration 53	g00702053

    10. Mark two points on the opposite sides of the bearing cage. The marks are illustrated above.
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    Illustration 54	g00702054

    11. Use a standard feeler gauge in order to measure the gap between the bearing cage and housing assembly (1) at the two marked points. Average the two measurements.
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    Illustration 55	g00575305

    12. Add 0.28 mm (0.011 inch) to the average measurement that was found in step 36.k in order to achieve the shim pack thickness. Install shims (57) .

    13. The desired bearing end play is .12 ± 0.07 mm (0.005 ± 0.003 inch).

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Illustration 56	g00577404

37. Install six bolts (54) and washers in bearing cage (55) .

38. Measure the end play for the output shafts. The end play should be 0.12 ± 0.07 mm (0.005 ± 0.003 inch).

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Illustration 57	g00575299

39. Install O-ring seal (53) on tube assembly (51) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (53) .

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Illustration 58	g00575298

40. Install tube assembly (51) in case assembly (1) .

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Illustration 59	g00575296

41. Install three bolts (52) in tube assembly (51) .

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Illustration 60	g00575295

42. Install manifold assembly (50) , as shown.

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Illustration 61	g00575294

43. Install two bolts (49) that hold manifold assembly (50) to case assembly (1) .

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Illustration 62	g00578466

44. Install tube assembly (48) .

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Illustration 63	g00575291

45. Position the case assembly (1) , as shown. The weight of the case assembly (1) is approximately 1114 kg (2455 lb).

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Illustration 64	g00575288

46. Install O-ring seal (47) on tube assembly (44) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (47) .

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Illustration 65	g00575287

47. Install tube assembly (44) .

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Illustration 66	g00575284

48. Install O-ring seal (46) on tube assembly (45) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (46) .

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Illustration 67	g00575282

49. Install tube assembly (45) .

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Illustration 68	g00575281

50. Install three bolts (42) on tube assembly (44) . Install three bolts (43) on tube assembly (45) .

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Illustration 69	g00575273

51. Install O-ring seal (41) on tube assembly (39) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (41) .

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Illustration 70	g00575279

52. Install O-ring seal (40) on tube assembly (38) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (40) .

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Illustration 71	g00575249

53. Install tube assembly (38) in case assembly (1) . Install three bolts (36) on tube assembly (38) . Install tube assembly (39) in case assembly (1) . Install three bolts (37) on tube assembly (39) .

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Illustration 72	g00575275

54. Install two bolts (35) and clips.

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Illustration 73	g00575246

55. Lower temperature of roller bearing cup (34) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (34) in case assembly (1) . Allow temperature of roller bearing cup (34) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (34) in case assembly (1) .

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Illustration 74	g00578742

56. Raise temperature of roller bearing cone (32) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (32) on gear (31) . Allow temperature of roller bearing cone (32) to stabilize. Use a brass drift to seat roller bearing cone (32) on gear (31) .

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Illustration 75	g00578274

57. Raise temperature of roller bearing cone (33) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (33) on gear (31) . Allow temperature of roller bearing cone (33) to stabilize. Use a brass drift to seat roller bearing cone (33) on gear (31) .

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Illustration 76	g00575242

58. Install gear (31) in case assembly (1) .

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Illustration 77	g00575236

59. Lower the temperature of roller bearing cup (28) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (28) in bearing cage (24) . Allow temperature of roller bearing cup (28) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (28) in bearing cage (24) .

    Note: Make sure that O-ring seal (29) is not installed on bearing cage (24) at this time.

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Illustration 78	g00577405

60. Install Tooling (C) in case assembly (1) . Install bearing cage (24) on case assembly (1) .

61. Use the following procedure in order to seat the bearings:
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    Illustration 79	g00577406

    1. Install four bolts (27) in bearing cage (24) . Tighten four bolts (27) to 34 N·m (25 lb ft). Tighten bolts (27) in an alternating sequence until all bolts (27) are at a torque of 34 N·m (25 lb ft).
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    Illustration 80	g00615720

    2. Use a pry bar in order to rotate the output shaft assembly (79) at least one revolution.

       Note: Output shaft (79) will be pointing downward at this time.

    3. Repeat Step 61.a and Step 61.b until the torque stabilizes.
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    Illustration 81	g00615589

    4. Tighten four bolts (27) to 68 N·m (50 lb ft). Tighten bolts (27) in an alternating sequence until all bolts (27) are at a torque of 68 N·m (50 lb ft).
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    Illustration 82	g00615720

    5. Use a pry bar in order to rotate the output shaft assembly (79) at least one revolution.

    6. Repeat Step 61.d and Step 61.e until the torque stabilizes. Loosen four bolts (27) .
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    Illustration 83	g00577406

    7. Tighten four bolts (27) to 3.4 N·m (30 lb in). Alternate between opposite bolts.
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    Illustration 84	g00615720

    8. Use a pry bar in order to rotate the output shaft assembly (79) at least three revolutions.

       Note: The output shaft (79) will be pointing downward at this time.

    9. Repeat Step 61.g through Step 61.h until the torque stabilizes.
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    Illustration 85	g00702056

    10. Mark two points on the opposite side of the bearing cage. The marks are illustrated above.
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    Illustration 86	g00702061

    11. Use a standard feeler gauge in order to measure the gap between the bearing cage and the housing assembly (1) at the two marked points. Average the two measurements.
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    Illustration 87	g00577409

    12. Add the average thickness from Step 61.k with 0.25 mm (0.010 inch). This is the thickness of the shims that should be installed. Install shims (30) .

    13. The desired bearing end play is .12 ± .07 mm (0.005 ± 0.003 inch).

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Illustration 88	g00575236

62. Install O-ring seal (29) on bearing cage (24) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (29) .

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Illustration 89	g00577405

63. Install bearing cage (24) . Remove Tooling (C) .

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Illustration 90	g00615630

64. Install four bolts (27) , as shown.

65. Measure the end play for the output shafts. The end play should be .12 ± .07 mm (0.005 ± 0.003 inch).

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Illustration 91	g00575210

66. Install coupling (25) in seal adapter (23) . Install two ring seals (26) in seal adapter (23) .

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Illustration 92	g00575209

67. Install seal adapter (23) in cage assembly (24) .

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Illustration 93	g00575207

68. Lower temperature of roller bearing cup (22) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (22) in case assembly (1) . Allow temperature of roller bearing cup (22) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (22) in case assembly (1) .

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Illustration 94	g00578501

69. Raise temperature of roller bearing cone (20) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (20) on gear (19) . Allow temperature of roller bearing cone (20) to stabilize. Use a brass drift to seat roller bearing cone (20) on gear (19) .

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Illustration 95	g00578275

70. Raise temperature of roller bearing cone (21) to 135° ± 14°C (275° ± 25°F). Install roller bearing cone (21) on gear (19) . Allow temperature of roller bearing cone (21) to stabilize. Use a brass drift to seat roller bearing cone (21) on gear (19) .

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Illustration 96	g00575199

71. Install gear (19) in case assembly (1) .

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Illustration 97	g00575194

72. Lower the temperature of roller bearing cup (16) to -46° ± 6°C (-50° ± 10°F). Install roller bearing cup (16) in bearing cage (13) . Allow temperature of roller bearing cup (16) to stabilize. Use Tooling (A) (not shown) in order to seat roller bearing cup (16) in bearing cage (13) .

    Note: Make sure that O-ring seal (17) is not installed on bearing cage (13) at this time.

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Illustration 98	g00577431

73. Install Tooling (C) in case assembly (1) . Install bearing cage (13) on case assembly (1) .

74. Use the following procedure in order to seat the bearings:
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    Illustration 99	g00577432

    1. Install four bolts (15) in bearing cage (13) , as shown. Tighten four bolts (15) to a torque of 34 N·m (25 lb ft). Torque the bolts (15) in an alternating sequence until all of the bolts are at the torque of 34 N·m (25 lb ft).
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    Illustration 100	g00615720

    2. Use a pry bar in order to rotate the output shaft assembly (79) at least one revolution.

       Note: The output shaft (79) will be pointing downward at this time.

    3. Repeat Step 74.a and Step 74.b until the torque stabilizes.
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    Illustration 101	g00615651

    4. Torque four bolts (15) in an alternating sequence and repeat until all of the bolts (15) stabilizes at 68 N·m (50 lb ft).
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    Illustration 102	g00615720

    5. Use a pry bar in order to rotate output shaft assembly (79) at least one revolution.

    6. Repeat Step 74.d and Step74.e until the torque stabilizes at 68 N·m (50 lb ft).
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    Illustration 103	g00615651

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    Illustration 104	g00615720

    7. Loosen four bolts (15) . Use a pry bar in order to rotate or oscillate output shaft assembly (79) in order to be certain that the components have end play. Loosen bolts (15) .
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    Illustration 105	g00615657

    8. Torque two bolts (15) in an alternating sequence and repeat until both of the bolts (15) stabilize at 3.4 N·m (30 lb in).
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    Illustration 106	g00615720

    9. Use a pry bar in order to rotate output shaft assembly (79) at least three revolutions.
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    Illustration 107	g00577455

    10. Use a standard feeler gauge in order to measure the gap between bearing cage (13) and housing assembly (1) at two points. The points should be at 180 degree. Average the two measurements.
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    Illustration 108	g00579378

    11. Add the average thickness from Step 74.j with 0.25 mm (0.010 inch). This is the thickness of the shims that should be installed. Install the shims (18) .

    12. The desired bearing end play is .12 ± 0.07 mm (0.005 ± 0.003 inch).

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Illustration 109	g00615721

75. Remove Tooling (D) from output shaft assembly (79) .

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Illustration 110	g00575194

76. Install O-ring seal (17) on bearing cage (13) . Apply 1U-6396 O-Ring Assembly Compound to O-ring seal (17) .

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Illustration 111	g00577431

77. Install bearing cage (13) . Remove Tooling (C) .

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Illustration 112	g00575189

78. Install six bolts (15) and washers on cage assembly (13) .

79. Measure the end play for the output shafts. The end play should be 0.12 ± 0.07 mm (0.005 ± 0.003 inch).

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Illustration 113	g00575187

80. Install two ring seals (14) on seal adapter (12) .

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Illustration 114	g00575185

81. Install seal adapter (12) in cage assembly (13) .

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Illustration 115	g00575182

82. Install tube assembly (11) .

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Illustration 116	g00575181

83. Install tube assemblies (7) , (8) , (9) , and (10) on case assembly (1) .

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Illustration 117	g00575180

84. Install tube assemblies (5) and (6) on case assembly (1) .

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Illustration 118	g00575178

85. Install tube assemblies (2) , (3) , and (4) on case assembly (1) .

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Illustration 119	g00577371

86. Install flange (72) .

    Note: Flange (72) is only splined to output shaft assembly.

End By: Connect the rear pump drive to the engine. Refer to Disassembly and Assembly, "Pump Drive (Rear) to Engine - Connect".