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

Wheel Loader

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; ZMX1-UP)

Introduction

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

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

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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

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

Clean all surfaces before you install any parts.

Reference: Parts Manual, SEBP5719 for S/N:8801-UP, Parts Manual, SEBP5775 for S/N:ZMX1-UP, Parts Manual, M0070136 for S/N:KK21-UP, and Parts Manual, M0070134 for S/N:RM21-UP. Refer to Operation and Maintenance Manual, SEBU8651 and Service Manual, KENR7580 for (S/N: 8801-UP; ZMX1-UP). Refer to Operation and Maintenance Manual, M0074690 and Service Manual, UENR7608 for (S/N: KK21-UP; RM21-UP).

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

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

Illustration 1	g02910496

Components and Weights

Illustration 2	g01473401

• Standard machine (1) without either axle has a weight of 61240 kg (135000 lb).

• Standard machine (1) with a high lift arm assembly without either axle has a weight of 62418 kg (137608 lb)

• Front axle housing (2) has a weight of 6465 kg (14250 lb).

• Rear axle housing (3) has a weight of 6760 kg (14900 lb).

Illustration 3	g01473113

• Cab (4) has a weight of 272 kg (600 lb).

• ROPS (5) has a weight of 2480 kg (5470 lb).

• Each wheel and tire (6) has a weight of 3135 kg (6910 lb).

Illustration 4	g06338360

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

Note: If the rear bumper assembly needs to be installed, use 16 8T-5878 Bolts and use 16 7X-0616 Hard Washers. Tighten the bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft). The weight of the rear bumper assembly is 5048 kg (11129 lb) with the standard lift arrangement. The weight of the rear bumper assembly is 5938 kg (13091 lb) with the high lift arrangement.

Preparation for Assembly

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Illustration 5	g02864483
Typical example

1. Park the trailer with the basic machine in the center of a large level area that has a good hard surface. Engage the parking brakes of the truck and place wood blocks between the trailer wheels.
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   Illustration 6	g02718089

2. Remove the panel near the top of the steps on the left side of the machine. The panel must be removed to install the rear axle assembly and the left rear tire. Set the panel aside for later installation.
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   Illustration 7	g00115505

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

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

Installation of the Front Axle

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Illustration 8	g00115507

1. Clean the mounting surfaces for the front axle under the front frame of the machine. Make sure that the machined surface is free of dirt.
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   Illustration 9	g00115509

2. Clean the mounting surfaces on the front axle housing. Make sure that the machined surface is free of dirt.
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   Illustration 10	g00115511

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

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

5. Use ten 6V-1734 Bolts (2) with 20 4K-0684 Washers (3) and with ten 3K-9770 Nuts (4) in order to secure each side of the front axle housing to the front frame. Tighten all bolts to a torque of 1800 ± 200 N·m (1325 ± 100 lb ft).
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   Illustration 11	g00443666

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   Illustration 12	g00115516

6. Attach lifting eyes and lifting cables to the lifting eyes on the front frame. Attach the crane to the lifting cables and raise the machine 58960 kg (129984 lb) in order to position blocking under the machine. The machine must be high enough to install the tires on the front axle.

Installation of the Rear Axle

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

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

2. Clean the mounting surfaces on the trunnions of the rear axle housing. Make sure that the machined surface is free of dirt.
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   Illustration 13	g00268348
   Typical example

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

4. Use 16 142-7074 Bolts (2) and use 16 9M-2828 Hard Washers (3) to secure the rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).
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   Illustration 14	g01473053

5. Use six 142-7074 Bolts (2) and use six 9M-2828 Hard Washers (3) to secure the front rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).
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   Illustration 15	g00268350
   Typical example

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

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

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Illustration 16	g06338362

1. Connect front drive shaft (1) to the front differential. Install four 9X-6480 Bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).
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   Illustration 17	g01469267

2. Connect 312-3653 Tube As (3) to the port on the front of the axle.
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   Illustration 18	g02718096
   Left side of front axle (rear view) (4) 347-8702 Tube As (5) 6D-4246 Clip (6) 8T-8513 Clip (7) 5K-9660 Clip (8) 8R-8087 Spacer (9) 346-4438 Tube As (10) 7M-8798 Clip (11) 8T-6466 Bolt (12) 8T-4121 Hard Washer

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   Illustration 19	g02718103
   Inside loader frame above front axle (4) 347-8702 Tube As (9) 346-4438 Tube As (13) 115-2516 Block (14) 115-2516 Block (15) 291-5620 Tube As (16) 264-8087 Tube As

3. Connect one end of 347-8702 Tube As (4) to the left side of 115-2516 Block (13). 347-8702 Tube As (4) is the left return line for the axle oil cooler.

4. Connect one end of 346-4438 Tube As (9) to 115-2516 Block (14). 346-4438 Tube As (9) is the left service brake line.

5. Connect the opposite end of 347-8702 Tube As (4) to the left brake housing. Connect the opposite end of 346-4438 Tube As (9) to the left brake housing.

6. Attach the tubes to the front frame. Use one 8F-8513 Clip (6), one 5K-9660 Clip (7), one 8T-6466 Bolts (11), one 8T-4121 Hard Washer (12), and one 8R-8087 Spacer (8).

   Attach 6D-4246 Clip (5) and 7M-8798 Clip (10) to the tubes. Do not attach these clips to the axle now.

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   Illustration 20	g01469812
   Left side of front axle (rear view) (17) 1F-1609 Spacer (18) 5P-1076 Hard Washer (19) 8T-4648 Bolt (20) 8T-6466 Bolt (21) 7X-7729 Washer (22) 138-4409 Spacer (23) 230-7680 Guard As

7. Install 230-7680 Guard As (23) over the tubes. Use two 1F-1609 Spacers (17), two 5P-1076 Hard Washers (18), and two 8T-4648 Bolts (19) to secure the guard to the brake housing.

   Use 8T-6466 Bolt (20), 7X-7729 Washer (21), and 138-4409 Spacer (22) to secure the guard to the axle housing. Place boss (22) between the guard and the clips that were attached to the tubes in Step 6.

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   Illustration 21	g01469268
   Right side of front axle (rear view) (6) 8F-8513 Clip (10) 7M-8798 Clip (12) 8T-4121 Hard Washer (15) 347-8701 Tube As (16) 346-4439 Tube As (24) 6D-4244 Clip (25) 8T-4196 Bolt (26) 2S-4762 Clip

8. Install 346-4439 Tube As (16) and 347-8701 Tube As (15) on the right side of the front axle. 347-8702 Tube As is the right service brake line. 347-8701 Tube As is the right return line for the axle oil cooler.

9. Install 230-7679 Guard As over the tubes on the right side of the axle.
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   Illustration 22	g02718111
   Front axle (rear view)

10. Connect front wiring harness (27) to the wiring harness for the temperature sensor on the axle. Use three tie straps (28) to secure the harness to the axle housing.
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    Illustration 23	g01469908

11. Connect 317-5602 Hose As (29) to the port at the bottom of the differential.
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    Illustration 24	g01469910

12. Install 317-9193 Guard (30) on the axle housing. Use two 7X-0389 Bolts and two 242-0315 Spacers to install the plate.

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

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Illustration 25	g00268356

1. Connect the rear drive shaft (1) to the rear differential. Install four 9X-6480 Bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).
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   Illustration 26	g02718678
   Front trunnion (top view) (3) 204-8000 Cable Tie Mounting (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer (6) 204-2281 Cable Strap

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   Illustration 27	g02718697
   (7) 286-7269 Bracket (8) 8T-4195 Bolt (9) 8T-4121 Hard Washer (10) 4V-1939 Clamp (11) 5V-6439 Plate (12) 7X-2534 Bolt (13) 9X-8256 Washer (14) 337-3359 Bracket As (15) 8T-4137 Bolt

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   Illustration 28	g02718740
   Rear axle (front view) (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer (8) 8T-4195 Bolt (16) 142-1657 Bracket As (17) 130-5300 Clip (18) 373-2449 Axle Temperature Wiring Gp

2. Connect 313-4443 Axle Harness (18) to temperature sensor (6).

   Note: Ensure that the harness is not stretched when the axle oscillates.

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   Illustration 29	g02717346
   Rear axle (front view) (19) 315-4138 Hose As (20) 115-2516 Block (21) 314-7943 Hose As (22) 115-2516 Block (23) 347-2308 Tube As (24) 346-0636 Hose As

3. Connect 314-7943 Hose As (21) to 115-2516 Block (22).

4. Connect 315-4138 Hose As (719) to 115-2516 Block (20).

5. Connect 347-2308 Tube As (23) to the top of the front trunnion support.

6. Connect 346-0636 Hose As (24) to the axle housing.
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   Illustration 30	g02717349
   Rear axle (rear view) (25) 347-2305 Tube As (26) 275-7769 Hose As

7. Connect 347-2305 Tube As (25) to the top of the rear trunnion.

8. Connect 275-7769 Hose As (26) to the top of the rear axle.

Installation of the Tires

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Illustration 31	g01489274

1. Install two 138-8698 Rods into one of the wheels of the front axle. The rods will be used to help guide the tire and rim onto the wheel.
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   Illustration 32	g00115530

2. Use a hoist and use a sling to install the front tires. The valve stem should be facing outward when the tires are installed. Install a 2J-3507 Full Nut with a 5P-8250 Washer onto each of the rods to hold the tire and rim assembly in place.
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   Illustration 33	g00115531

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

   Note: After installation of the rims/tires is completed, paint bolts and unpainted surfaces between the rim and final drive to prevent premature rust/corrosion.

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

5. After the tires have been installed on the machine, remove the truck trailer.
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   Illustration 34	g02718138

6. Reinstall the panel on the left side of the machine.

Installation of the Cab

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Illustration 35	g02723554

1. Attach an appropriate lifting device to the top of the cab. Lift the cab into position above the mounts.
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   Illustration 36	g02723559
   Right rear corner of cab

2. Route the machine wiring and air conditioner hoses into the right rear compartment on the cab.
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   Illustration 37	g03358722

3. Place a 346-8408 Spacer on each mount. Assemble one 086-0299 Washer to each 8T-4141 Bolt. Assemble the bolts through the floor of the cab, through the spacers and into the mounts. Hand thread a 8T-4141 Bolt into each mount (five turns). Lower the cab onto the cab mounts.

4. Remove the panel below the rear window on the outside of the cab.
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   Illustration 38	g03358719

5. Tighten down the four 8T-4141 Bolts. Torque to 460 ± 60 N·m (339 ± 44 lb ft)
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   Illustration 39	g02723569

6. Install one 243-1175 Cover over each cab mount. Use four 8T-4138 Bolts to install each cover.
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   Illustration 40	g02718141
   Right rear compartment of cab

7. Attach the air conditioner hoses that are inside the right rear compartment on the cab. Attach 346-0991 Hose As (1) to the upper port on the air conditioner. Torque this connection to 54 ± 5 N·m (40 ± 4 lb ft). Connect the 342-9781 Hose As (2) to the lower port on the air conditioner. Torque this connection to 80 ± 5 N·m (60 ± 4 lb ft).
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   Illustration 41	g02718142
   Detail of hoses for the heater (bottom of cab, right side view) (3) 9X-2488 Hose Clamp (4) 5P-0767 Hose

8. Attach the hoses for the heater to the tubes that are in the right rear compartment of the cab.
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   Illustration 42	g02718930
   Right rear compartment of cab

9. 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 43	g02718932

10. Connect the camera and power cable for the cab. Use the hardware supplied on the connector to install the power cable for the cab.
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    Illustration 44	g06338364

11. Secure harness with provided P-Clip (1) in order to prevent cable chaffing.
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    Illustration 45	g02718144
    Underside of front of cab

12. Attach service brake control valve (6) to the bottom of the cab. Use four 8T-4133 Nuts and four 8T-4121 Hard Washers to attach the valve.
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    Illustration 46	g02714438
    Right side of machine under the cab

13. Attach the parking brake control cable to the linkage.
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    Illustration 47	g02714439
    Underside of right side of cab

14. Connect the steering neutralizer lines group to the manifold on the bottom of the cab. Refer to Illustration above for the hose routing.

Installation of Steps and Handrails

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Illustration 48	g02714443
(1) 375-7741 Handrail As (2) 375-7743 Handrail As (3) 8T-4139 Bolt (4) 7X-3392 Hard Washer (5) 355-9649 Step Gp (6) 8T-4194 Bolt (7) 5P-1076 Hard Washer

1. Install 375-7741 Handrail As (1) to the left rear bumper. Use two 8T-4139 Bolts (3) and two 7X-3392 Hard Washers (4).

2. Install 375-7743 Handrail As (2) to the left rear bumper. Use two 8T-4139 Bolts (3) and two 7X-3392 Hard Washers (4)

3. Install 355-9649 Step Gp (5) to the left rear bumper. Use four 8T-4194 Bolts (6), and four 5P-1076 Hard Washers (7).

4. Repeat Steps 1 through Step 3 to install the handrails and Step Gp for the right side of the machine. Use the same parts and hardware.
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   Illustration 49	g02868316
   (8) 362-0935 Handrail As (9) 8T-4139 Bolt (10) 7X-3392 Hard Washer

5. Install 362-0935 Handrail As (8) to the left rear bumper. Use four 8T-4139 Bolts (9), and four 7X-3392 Hard Washers (10).
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   Illustration 50	g02874566

6. On the same 362-0935 Handrail As at the back of the bumper: Secure the handrail As (8) using two 8T-4195 Bolts (9A), and two 7X-3392 Hard Washers (10).

7. Repeat Step 1 through Step 6 to install 362-0936 Handrail As to the right side of the machine. Use the same hardware.
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   Illustration 51	g02714447
   (11) 375-7739 Handrail As (12) 8T-4139 Bolt (13) 7X-3392 Hard Washer

8. Install 375-7739 Handrail As (11) to the left rear bumper. Use four 8T-4139 Bolts (12), and four 7X-3392 Hard Washers (13).

9. Repeat Step 8 to install 375-7739 Handrail As to the right side of the machine. Use the same hardware.
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   Illustration 52	g02714448
   (14) 365-0700 Handrail As (15) 8T-4139 Bolts (16) 7X-3392 Hard Washer

10. Install 365-0700 Handrail As (14) to the left stairway. Use eight 8T-4139 Bolts (15), and eight 7X-3392 Hard Washers (16).

11. Repeat Step 10 to install 365-0706 Handrail As to the right side of the machine. Use the same hardware.
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    Illustration 53	g02714449
    (17) 359-1109 Handhold As (18) 8T-4139 Bolt (19) 7X-3392 Hard Washer

12. Install 359-1109 Handhold As (17) to the inside left rear stairway. Use four 8T-4139 Bolts (18), and four 7X-3392 Hard Washers (19).

13. Repeat Step 12 to install 359-1114 Handhold As the right side of the machine. Use the same hardware.
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    Illustration 54	g02714450
    (20) 343-8725 Handrail As (21) 359-1103 Handrail As (22) 359-1104 Handhold As (23) 9X-2040 Screw

14. Assemble three handrails together. Assemble 343-8725 Handrail As (20), 359-1103 Handrail As (21), and 359-1104 Handhold As (22). Use eight 9X-2040 Screws (23).
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    Illustration 55	g02714452
    (24) 8T-4139 Bolt (25) 7X-3392 Hard Washer

15. Install the handrail to the left platform. Use eight 8T-4139 Bolts (24), and eight 7X-3392 Hard Washers (25).
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    Illustration 56	g02714453
    (26) 359-1104 Handhold As (27) 359-1103 Handrail As (28) 365-0744 Handrail As (29) 9X-2040 Screws

16. Assemble four handrails together for the right platform. Assemble 359-1104 Handhold As (26), two 359-1103 Handrail As (27), and 365-0744 Handrail As (28). Use 12 9X-2040 Screws (29).
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    Illustration 57	g02714454
    (30) 8T-4139 Bolts (31) 7X-3392 Hard Washer

17. Install the handrail assembly to the right platform. Use 16 8T-4139 Bolts (30), and 16 7X-3392 Hard Washers (31).
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    Illustration 58	g02714455
    (32) 365-3624 Handrail As (33) 8T-4139 Bolt (34) 7X-3392 Hard Washer

18. Install 365-3624 Handrail As (32) to the left platform. Use six 8T-4139 Bolts (33), and six 7X-3392 Hard Washers (34).
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    Illustration 59	g02714457
    (42) 366-1721 Step As (43) 8T-4139 Bolt (44) 5P-1076 Hard Washer

19. Install 366-1721 Step As (42) to the left platform. Use six 8T-4139 Bolts (43), six 5P-1076 Hard Washers (44).

20. Repeat Step 19 to install the 366-1722 Step As onto the right platform. Use the same hardware.
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    Illustration 60	g02714459
    (45) 366-1724 Handhold As (46) 8T-4139 Bolt (47) 7X-3392 Hard Washer

21. Install 366-1724 Handhold As (45) to the left Step on the platform. Use four 8T-4139 Bolts (46), and four 7X-3392 Hard Washers (47).

22. Repeat Step 21 using 366-1725 Handhold As. Use the same hardware.
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    Illustration 61	g02714461
    (49) 323-3746 Bracket (50) 323-3747 Bracket (51) 8T-4195 Bolt (52) 7X-7729 Washer (53) 127-0366 Spacer (54) 8T-6466 Bolt (55) 096-4883 Locknut

23. Install 343-8721 Gate As (48) to the left platform. Use the hardware listed above for the top and bottom hinge.
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    Illustration 62	g02714467
    (56) 351-8984 Bracket (57) 8T-4195 Bolt (58) 7X-7729 Washer (59) 248-0102 U-Bolt (60) 5C-7261 Nut (61) 8T-4224 Hard Washer (62) 300-4511 Latch As

24. Install the latch for the gate assembly. Use the hardware listed above to install the latch.
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    Illustration 63	g03490796
    (62) 300-4511 Latch As (K) 25 mm (0.98 inch)

25. Orient Latch As (62) for proper assembly and clearance. Refer to Illustration 63.
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    Illustration 64	g02714470
    (63) 366-1729 Guard Plate (64) 365-0720 Guard Plate (65) 362-0940 Guard Plate (66) 346-6895 Guard Plate (67) 8T-4139 Bolt (68) 5P-1076 Hard Washer (69) 8T-4192 Bolt (70) 8T-3597 Weld Nut

26. Install the toe guards to the handrails on the left platform. Use the toe guards and hardware listed above.
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    Illustration 65	g02714472
    (71) 349-5616 Guard Plate (72) 346-6893 Guard Plate (73) 365-0719 Guard Plate (74) 366-1729 Guard Plate (75) 8T-4139 Bolt (76) 5P-1076 Hard Washer

27. Install the toe guards to the handrails on the right platform. Use the toe guards and hardware listed above.

    71

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    Illustration 66	g02714474
    (77) 5P-7468 Clip (78) 5P-7469 Clip (79) 6V-1874 Grommet (80) 8T-4194 Bolt (81) 7X-3392 Hard Washer (82) 8T-4244 Nut

28. Secure the left-hand stairway handrail to handrail on the left platform. Use the hardware listed above.

29. Repeat the above step for the right side of the machine.
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    Illustration 67	g02714480
    (83) 5P-7468 Clip (84) 5P-7469 Clip (85) 6V-1874 Grommet (86) 115-3580 Plate (87) 8T-4183 Bolt (88) 8t-4223 Hard Washer (89) 8T-4244 Nut

30. Secure the front step handrail to the handrail on the left platform. Use the hardware listed above.

31. Repeat the above step for the right side of the machine.

Installation of Product Link (if equipped)

Illustration 68	g02727731
(1) 263-9088 Communication Radio Gp (2) 290-2227 Plate As (3) 6V-8490 Bolt (4) 8T-4205 Hard Washer

1. Attach 263-9088 Communication Electronic Control Module (1) to the 290-2227 Plate As (2). Use four 6V-8490 Bolts and four 8T-4205 Hard Washers to connect the module to the plate.
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   Illustration 69	g02727717
   (1) Communication ECM (5) HID lamp (if equipped) (6) Flood lamp

2. Mount the plate with the communication ECM to the underside of the ROPS. Use two 8T-4121 Hard Washers and two 8T-4136 Bolts to mount the plate to the canopy. Connect the ROPS wiring to the communication ECM.
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   Illustration 70	g03642750
   (7) 270-8544 Bracket As (8) 8T-4137 Bolt (9) 8T-4121 Hard Washer (10) 310-2391 Antenna As (11) 9X-6772 Cable Strap

3. Attach 270-8544 Bracket As (7) to the right side of the ROPS canopy. Use two 8T-4137 Bolts and two 8T-4121 Hard Washers to attach the bracket.

4. Attach 310-2391 Antenna As (10) to 270-8544 Bracket As. Tighten the nut on the antenna to 5.0 ± 0.5 N·m (45 ± 4 lb in). Use one 9X-6772 Cable Strap (11) to strap the antenna cable to the link on the outside of the canopy. Use an extra cable strap to strap the cable to the link on 270-8544 Bracket As.

5. Attach the antenna cable to the communication ECM. Use five 9X-6772 Cable Straps (11) to strap the cable to the underside of the ROPS canopy.

Radio Antenna - Install

Note: The following procedure applies only to machines that are equipped with a radio.

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Illustration 71	g02727725

1. Attach 9U-2334 Coaxial Cable As (1) to the antenna connector on the left side of the bottom of the ROPS canopy.
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   Illustration 72	g02727727

2. Attach 9U-2332 Antenna As (2) to the antenna connector of the left side of the top of the ROPS canopy.
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   Illustration 73	g02727728

3. Attach 9U-2329 Coaxial Cable As (3) to the antenna connector on the right side of the bottom of the ROPS canopy.
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   Illustration 74	g02727729

4. Attach 9U-2331 Antenna As (4) to the antenna connector on the right side of the top of the ROPS canopy.

Installation of the ROPS

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Illustration 75	g02718149

1. Remove 339-4691 Panel (1) from the right side of the platform and remove 339-4690 Panel (2) from the left side of the platform. To install the ROPS, the pictured cover assemblies are to be removed.
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   Illustration 76	g00443235
   Typical example

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

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

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   Illustration 77	g02718154

3. Clean the ROPS mounting surface that is on the machine. Clean the ROPS mounting surface that is on the ROPS.
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   Illustration 78	g00443649
   Typical example

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

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

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   Illustration 79	g01493613

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

5. Secure the ROPS with 20 8C-3236 Bolts (3) and 20 3S-7023 Washers (4) on each side of the ROPS. Tighten the bolts to a torque of 1600 ± 200 N·m (1200 ± 150 lb ft).

6. Reinstall 113-6026 Cover Assembly (1) and 113-6027 Cover Assembly (2) that were removed in Step 1.
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   Illustration 80	g02718155

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

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

Illustration 81	g02864491

1. Place 314-9291 Film (1) onto 349-5595 Cover (2).

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

2. Install 302-5176 Cover (2) onto the top rear of the ROPS.
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   Illustration 82	g02342770

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

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

5. Torque the bolt to 35 N·m (26 lb ft).
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   Illustration 83	g02342458

6. Connect the wire harness to each 353-2833 Flood Lamp Gp (12). Mount one floodlight on the left front corner of the ROPS. Mount one floodlight on the right front corner of the ROPS. Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), 7X-7729 Hard Washer , (9), and 8T-4195 Bolt (6).
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   Illustration 84	g02342846

7. Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the right rear side of the radiator guard with 4E-8976 Bracket (14). Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6).
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   Illustration 85	g02342855

8. Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the left rear side of the radiator guard with 4E-8975 Bracket. Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6).
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   Illustration 86	g02864499

9. Place 314-9291 Film (16) onto 9U-3663 Plate Assembly (17).

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

10. Mount 9U-3663 Plate Assembly (17) onto the front of the ROPS with five 6V-3822 Bolts (19) and five 6V-5839 Washers (20).
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    Illustration 87	g02342943

11. Install 315-3460 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 88	g02342958

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

13. 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 89	g02342960
    Installation of right side mirror (29) 5P-6879 Mirror (30) 6K-5290 Clip (31) 6K-5291 Clip (32) 5P-7468 Clip (33) 5P-7469 Clip (34) 6V-1874 Grommet (35) 7X-0563 Hard Washer (36) 7X-7729 Washer (37) 8T-0389 Locknut (38) 8T-4185 Bolt (39) 8F-0492 Spacer (40) 8T-4195 Bolt (41) 7U-1903 Support

14. Install mirrors on the handrails on each side of the cab. Refer to Illustration 89.
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    Illustration 90	g02718157

15. Position the exhaust stacks (45) over the holes in the hood. Secure the exhaust stacks to the top of the hood. Use four 8T-4183 Bolts (46) and four 5P-1076 Hard Washers on each exhaust stack.
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    Illustration 91	g02723584

16. Install the 333-1195 Precleaner As (47) onto the exhaust plenums.

HID Lights (If Equipped)

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Illustration 92	g02342877

1. Connect the wire harness to each 347-9427 Flood Lamp Gp (1) and 332-9402 Flood Lamp Gp (2). Mount flood lamps (1) and (2) to the top left and right corners of the ROPS. Mount both the left and right side floodlights with 373-1524 Bracket (3), two 7X-7729 Washers (4) and two 8T-4195 Bolts (5). Repeat this step on the opposite side of the machine.
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   Illustration 93	g02342897

2. Connect the wire harness to each 347-9427 Flood Lamp Gp (1). Mount flood lamp (1) to the top left and right corners of the radiator guard. Mount the right side floodlight with 283-9815 Bracket (7), four 8T-4121 Washers (6), and four 8T-4195 Bolts (5).
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   Illustration 94	g02342917

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

Heated Mirrors (if equipped)

Illustration 95	g02377257
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. Refer to Illustration 95. Use two 9X-6772 Cable Straps (1) 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 96	g02717299
(5) Heated mirror switch

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

Installation Of The Bucket

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

Table 1

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

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

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

3. Align the pin bores in the lift arm with the pin bores on the bucket.
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   Illustration 97	g01471972
   311-1898 Cartridge As (1) Oil port (A) 120 degree angle

4. Insert a 311-1898 Cartridge As into the B-pin joint on the right side of the machine. Install the cartridge so that the smaller diameter is toward the centerline of the machine. The dowel holes in the cartridge should face away from the machine. Push the cartridge through the lift arm until the inboard end of the cartridge is resting in the inside bore of the bucket hinge plate. Orient the cartridge so that the oil port on the cartridge is positioned within 60 degrees of the top of the cartridge. Refer to Illustration 97.
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   Illustration 98	g01472090
   Tooling for installation of B-pin (2) 289-0013 Puller Stud (3) Two 3S-6162 Hard Washers (4) 322-0101 Plate (5) 318-2117 Plate (6) Two 8H-3390 Full Nuts (7) 318-2120 Plate (8) 6V-0014 Hydraulic Cylinder Gp with 6V-2073 Bushing

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

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

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

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

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

10. Begin to press the cartridge into the bore.
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    Illustration 99	g01472136
    B-pin (sectional view) (9) 9S-8009 O-Ring Plug (10) 281-7190 Retainer (11) 316-6506 Spacer

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

12. Install 316-6506 Spacer (11) on top of retainer (10).
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    Illustration 100	g01472414
    (9) 9S-8009 O-Ring Plug (12) 4K-1388 O-Ring Seal

13. Insert 241-4960 Shims on top of spacer (11) to minimize the gap between the spacer and the plug. Assemble 4K-1388 O-Ring Seal (12) to 9S-8009 O-Ring Plug (9). Install 9S-8009 O-Ring Plug (9) on top of the shims.
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    Illustration 101	g01472416
    Alignment of dowel holes

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

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

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

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

18. Thoroughly clean the pin bores of the bucket and the bucket links. Apply 5P-3931 Anti-Seize Compound to the pin bore of the bucket and the bucket links.
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    Illustration 102	g01472452

19. Use a suitable lifting device to raise bucket link (13) into position. The weight of bucket link (13) is approximately 544 kg (1200 lb) for the standard lift machine. The weight of bucket link (13) is approximately 580 kg (1280 lb) for the high lift machine. Align the bores in bucket link (13) with the bores in the bucket.
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    Illustration 103	g01472453

20. Install 4E-5597 Pin As (14) into the bore.
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    Illustration 104	g01466588

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

22. Repeat Step 19 through Step 21 for the C-pin joint on the opposite side of the machine.
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    Illustration 105	g02454564
    (17) 372-2479 Block (18) 8T-4648 Bolt (19) 8T-4223 Hard Washer

23. Remove block (17), bolts (18), and washers (19) from both sides of the machine before operation.

    Note: Retain the block and hardware for future transportation of the machine.

    Note: Step 23 is ONLY for High Lift machines.

24. After both pins have been fully installed in the C-pin joints, cycle the lift arms several times. The cycles need to be from the fully lowered position to the fully raised position. Also, tilt the bucket several times through the full range of motion. This procedure will center the lift arms in the bucket hinge plate. The sides of the machine must be level to properly center the lift arms. Check the lift arms to confirm that the lift arms are centered in the bucket hinge plate.
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    Illustration 106	g01493700

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

Steering Neutralizer Valve Adjustment

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

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

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

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

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

5. Move the steering lever fully to the left so the machine articulates at the maximum speed. Engage the parking brake when the machine stops moving.
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   Illustration 107	g00554399
   Lower articulation hitch (left side view) (1) Steering stop on loader frame. (2) Steering stop on engine end frame.

6. Measure the clearance that exists between steering stop (1) and steering stop (2). The clearance should be a minimum of 19.05 mm (0.750 inch).
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   Illustration 108	g00554423
   (3) Adjustment screw for the steering neutralizer valve. (4) Steering neutralizer valve.

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

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

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

Commissioning Procedure

Make sure that all 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.

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.

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.

Calibration

Calibrations should be performed on a surface that is smooth and level. Allow enough room for movement of the linkage.

In addition to the calibrations that are listed in this document, perform any calibration that has an "Active Calibration Required (FMI 13)" fault.

Implement Linkage Sensors

1. Press the "HOME" key on the Advisor module to bring up the "HOME" menu. Select "Service". Press the "OK" key.

2. Select "Calibrations" from the "Service" menu. Press the "OK" key.

3. Select "Implement" from the "Calibrations" menu. Press the "OK" key.

4. Select "Linkage Sensors" from the "Implement" menu. Press the "OK" key.

5. The Advisor module may ask for a password. Enter the password. Press the "OK" key to continue.

6. Select "Lift Sensor Cal" from the "Linkage Sensors" menu. Press the "OK" key to begin the calibration of the lift linkage position sensor.

7. Follow the instructions that are shown on the Advisor display to perform the calibration.

8. Repeat Step 1 through Step 6 to calibrate the tilt linkage position sensor. Select "Tilt Sensor Cal" to calibrate the tilt linkage position sensor.

Implement Valve Solenoids

1. Press the "HOME" key on the Advisor module to bring up the "HOME" menu. Select "Service". Press the "OK" key.

2. Select "Calibrations" from the "Service" menu. Press the "OK" key.

3. Select "Implement" from the "Calibrations" menu. Press the "OK" key.

4. Select "Implement Valves" from the "Implement" menu. Press the "OK" key.

5. The Advisor module may ask for a password. Enter the password. Press the "OK" key to continue.

   Note: The default service mode password is "0". The service mode password can be changed using Electronic Technician.

6. Select "Raise Valve Cal" from the "Implement Valves" menu. Press the "OK" key to begin the calibration of the raise solenoids on the implement valve.

7. Follow the instructions that are shown on the Advisor display to perform the calibration.

   Repeat Step 1 through Step 6 to calibrate each of the implement valve solenoids. Select "Lower Valve Cal" to calibrate the lower valve solenoids. Select "Rack Valve Cal" to calibrate the rack valve solenoids. Select "Dump Valve Cal" to calibrate the dump valve solenoids. Select "Regen Valve Cal" to calibrate the tilt regeneration valve solenoid.

Payload Control System (PCS) Calibration

1. Press the "HOME" button on the Advisor module 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" key to continue.

   Note: The default service mode password is "0". The service mode password can be changed using Electronic Technician

5. Select "Empty Bucket Lift" from the "Calibrate Payload" menu. Press the "OK" button to begin the empty bucket calibration.

6. Follow the instructions that are shown on the Advisor display to run the calibration.

   Repeat Step 1 through Step 6 to complete the remaining calibrations. The remaining calibrations must be completed with a known weight in the bucket. Select "Full Bucket Lift" to perform the loaded bucket calibration. Select "Full Bucket Velocity" to perform the loaded bucket velocity compensation calibration.

7. Press the "HOME" button on the Advisor module to bring up the "HOME" menu. Select "Payload". Press the "OK" button.

8. Select "Advanced Configuration" from the "Payload" menu. Press the "OK" button.

9. Select "Calibration Weight" from the "Advanced Configuration" menu. Press the "OK" button.

10. Enter the weight used during the loaded bucket and loaded bucket velocity compensation calibrations. Press the "OK" button.

Target Weight for the Loader Bucket

Note: Refer to 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 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" key to continue.

   Note: The default service mode password is "0". The service mode password can be changed using Electronic Technician

5. Follow the instructions that are shown on the Advisor display to enter the target bucket weight.

Configure Payload Control System

Refer to Special Instruction, REHS4997, "994H Wheel Loader Assembly Procedure".

Activate Product Link

Refer to Special Instruction, REHS2365, "Installation Procedure for Product Link PL121SR and PL321" for information on how to activate and configure satellite Product Link.

Refer to Special Instruction, REHS2368, "Installation Procedure for Product Link PL522/523 (Cellular)" for information on how to activate and configure cellular Product Link.