990K Wheel Loader and 844K Wheel Dozer Machine Systems Caterpillar

Removal Procedure

Start by:

a. Remove the bucket lever and link.

b. Remove the tilt cylinder.

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Illustration 1	g06020208

1. Remove bolts (1) and position tube assemblies (2) out of the way.
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   Illustration 2	g06020209

2. Disconnect harness assembly (4). Disconnect tube assembly (3). Repeat for the opposite side.
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   Illustration 3	g01231404

3. Disconnect hose assembly (5). Repeat for the opposite side.
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   Illustration 4	g01231409

4. Adjust the height of Tooling (A) to a measurement of 1778 mm (70 inch). Position boom (6) onto Tooling (A).
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   Illustration 5	g01231418

5. Use Tooling (B) to secure lift cylinder assembly (7). The weight of cylinder (7) is approximately 726 kg (1600 lb). Remove bolt (8). Repeat for the opposite side.
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   Illustration 6	g01231423

6. Use Tooling (C) to remove collet (9). Repeat for the opposite side.
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   Illustration 7	g01231427

7. Retract pin (10) and attach a suitable lifting device to remove pin (10). The weight of pin (10) is approximately 50 kg (110 lb).

8. Remove pin (10). Repeat for the opposite side .

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Illustration 8	g01231429

1. Remove bolts (11). Remove plate (12). Repeat for the opposite side.
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   Illustration 9	g01231521

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   Illustration 10	g01231525

2. Attach a suitable lifting device onto boom (6). The weight of boom (6) is approximately 7890 kg (17395 lb).
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   Illustration 11	g01250031

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   Illustration 12	g01250045

3. Attach a suitable lifting device onto Tooling (D). The weight of Tooling (D) is approximately 172 kg (380 lb). Use Tooling (D) to retract pin assembly (13) and attach a suitable lifting device onto pin assembly (13). The weight of pin assembly (13) is approximately 77 kg (170 lb). Remove pin assembly (13). Repeat for the opposite side.
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   Illustration 13	g01250020

4. Remove boom (6) and position boom (6) on suitable blocking.

Installation Procedure

1. Install boom (6) in the reverse order of removal.

   1. Check and the replace lip seals to the lift cylinders if necessary. Apply Tooling (E) to bore prior to install the lip seals.

   2. Apply Tooling (F) to pin assemblies (10), (13).
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      Illustration 14	g06020210

   3. Apply Tooling (G) to collets (9) inner and outer surface. Install collets (9).

   4. Apply Tooling (G) onto the bolt. Install the bolt and nut (8). Tighten nut (8) to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft). Use a suitable hammer to strike collets (9) until the initial torque value is reduced to less than 950 N·m (701 lb ft). Tighten nuts again to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft). Use a suitable hammer to strike collets (9) until the torque value is reduced to less than 1600 N·m (1180 lb ft). Tighten nuts (8) to a final torque of 1800 ± 200 N·m (1328 ± 148 lb ft).

   5. Tighten nuts (8) to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft) after 50 hours of operation.