Hood Sheetmetal and Handrail Rework Procedure on Certain 994F and 994H Wheel Loaders {0635, 0679, 7251, 7256} Caterpillar

Wheel Loader

994F (S/N: 4421-UP)

994H (S/N: DWC1-UP)

Introduction

This Special Instruction will provide parts and rework procedure to strengthen the hood sheetmetal and handrail.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Required Parts

Remove and Install Procedure for front hood mount plate

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Illustration 1	g06116176
(A) Mount plate (B) 165.0 mm (6.50 inch) (C) 19.0 mm (0.75 inch) (D) 75.0 mm (3.00 inch) (E) 91.0 mm (3.60 inch) (F) 201.0 mm (7.91 inch) (G) 218.0 mm (8.60 inch) (H) Diameter is 24.5 mm (0.96 inch)

1. Fabricate the two mount plates (A) one for the left-hand side, and one the for right-hand side. As per the dimension shown in Illustration 1.
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   Illustration 2	g06116251
   (J) 165.0 mm (6.50 inch) (K) Mount plate 2 (L) 40.0 mm (1.60 inch) (M) 6.0 mm (0.24 inch)

2. Fabricate the mount plate (K) one for the left-hand side, and one for the right-hand side. As per the dimension shown in Illustration 2.
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   Illustration 3	g06116261
   (N) 8X-4765 Plate

3. Cut out existing 8X-4765 Plate (N), Including the weld on washer.
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   Illustration 4	g06116281
   (A) Mount plate (W1) 5.0 mm (0.20 inch) Fillet weld bottom of plate (P) 35.0 mm (1.38 inch) from bottom of upper plate to bottom of added plate

4. Weld mount plate (A) with 5.0 mm (0.20 inch) fillet weld to the same location as old plate. The weld on washer is no longer needed due to thicker plate.
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   Illustration 5	g06116288
   (K) Mount plate 2 (W2) 5.0 mm (0.20 inch) Fillet weld bottom of plate

5. Weld mount plate (K) with 5.0 mm (0.20 inch) fillet weld.

Rework Procedure for Rear Hood Cross Brace for both Right-Hand side and Left-Hand side

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Illustration 6	g06116305
(A) Brace block (B) 50.0 mm (1.97 inch) (C) Diameter is 12.5 mm (0.50 inch) (D) 50.0 mm (1.97 inch) (E) 250.0 mm (9.84 inch) (F) 25.0 mm (0.98 inch) (G) 50.0 mm (1.97 inch)

1. Fabricate brace block (A) for the left-hand side, and one for the right-hand side of the rear hood per the dimensions shown in Illustration 6.
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   Illustration 7	g06116308

2. Remove three weld nuts (H).
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   Illustration 8	g06116730
   (J) 55.0 mm (2.20 inch) (K) 15.0 mm (0.60 inch)

3. Cut the blue plate from the edge using the dimensions shown in Illustration 8.
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   Illustration 9	g06116732

4. Drill two holes (L) in line with the previous three holes, equally spaced 50.0 mm (1.97 inch).
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   Illustration 10	g06116733
   (A) Brace block (1) 7X-7729 Washer (2) 8T-4133 Nut (3) 222-9151 Hard Washer (4) 8T-4172 Bolt

5. Assemble the block (A) using ten washers (1), ten bolts (4), four washers (3), ten washers (1), and ten nuts (2) for both sides.

Rework Procedure for Firewall Support

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Illustration 11	g06116782
(A) 70.0 mm (2.76 inch) (B) 10.0 mm (0.40 inch) (C) 15.0 mm (0.60 inch) (D) 25.0 mm (1.00 inch) (E) 100.0 mm (3.94 inch) (F) 27.5 mm (1.08 inch) (G) 160.0 mm (6.30 inch) (H) Radius 27.5 mm (1.08 inch) (J) 10.0 mm (0.40 inch) (K) 27.5 mm (1.08 inch) (L) 125.0 mm (4.92 inch) (M) Plate

1. Fabricate support plate (M) for the right-hand side front , and rear right-hand side rear per the dimension shown in Illustration 11.
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   Illustration 12	g06116734
   (N) Boss

2. Remove boss (N). Add firewall support plate (M) to this area.

3. Reattach boss (N) in same location after the new plate (M) is added.
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   Illustration 13	g06116736
   (W1) 6.0 mm (0.24 inch) fillet weld (W2) 6.0 mm (0.24 inch) fillet weld (M) Plate

4. Weld new plate (L), 6.0 mm (0.24 inch) fillet weld all around the slot (W1) and weld location (W2) on both sides. Do NOT weld on sides of plate.
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   Illustration 14	g06116748
   (W3) 6.0 mm (0.24 inch) fillet weld (W4) 6.0 mm (0.24 inch) fillet weld (W5) 6.0 mm (0.24 inch) fillet weld

5. Weld area (W4) to (W5) as shown in illustration 14. Weld 6.0 mm (0.24 inch) at location (W3).
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   Illustration 15	g06116749
   (P) 25.0 mm (1.00 inch) (R) 10.0 mm (0.40 inch) (S) Radius is 25.0 mm (1.00 inch)

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   Illustration 16	g06116751

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   Illustration 17	g06116753

6. Make the cutouts as shown in Illustration16 and Illustration 17. Details for the cutout dimensions are shown in Illustration 15. Grind edges of cuts to remove gouges caused by cutting process.
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   Illustration 18	g06116756
   (W6) 6.0 mm (0.24 inch) fillet weld (W7) 6.0 mm (0.24 inch) fillet weld

7. Weld channel (W6) to (W7) as shown in Illustration 18. This weld is in additional to the existing weld on the inside of the channel at both ends.

Rework Procedure for Frame Mount both Left-Hand side and Right-Hand side

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Illustration 19	g06116760
(A) 114.3 mm (4.50 inch) (B) 12.7 mm (0.50 inch) (C) 177.8 mm (7.00 inch) (D) 127.0 mm (5.00 inch) (E) Frame plate (F) Radius is 77.0 mm (3.03 inch)

1. Fabricate four frame plate (E). Two for the right-hand side, two for the left-hand side rest. Frame plate dimensions are shown in Illustration 19.

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Illustration 20	g06116769
(G) 10.0 mm (0.40 inch) (H) 18.0 mm (0.71 inch)

1. Weld repair any existing cracks.

2. Weld new plate (E) 8.0 mm (0.31 inch) with a fillet weld around the entire plate, over weld the new plate over the existing plate as shown in Illustration 20.

3. Weld one plate (E) on the outside of the frame in location shown and the other plate (E) on the inside of the frame at same location. Repeat on opposite side of frame.

Rework Procedure for Platform Sheet Metal 994F Wheel Loaders

Illustration 21	g06014132
Typical damage to rear platform

Gusset Fabrication

The procedure will require the fabrication of 4 gussets (1). The gussets will be fabricated from 6.4 mm (0.25 inch) steel plate. Refer to Illustration 22 and Table 2 for dimensions of gusset (1).

Illustration 22	g06013501
Gusset (1)

Right Rear Platform Repair

Illustration 23	g06013781
Rear platform

The areas indicated in illustration 23 will be the areas covered in this section.

The procedure that follows will focus on the repair of a crack to the right rear platform.

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Illustration 24	g06014245

1. Weld the cracks (A) in the channel or replace with a reinforcement plate.

   Note: Weld only the damaged area, DO NOT weld the top and bottom (B) of the channel.

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   Illustration 25	g06014258
   Bottom view

2. Remove the bolt securing the clip. Secure the harness away from the effected area to avoid damaging the harness.
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   Illustration 26	g06014302
   Bottom view

3. Locate the gusset (1) on the bottom of the channel using the two existing holes in the channel. Weld the gusset (1) to the platform using the two slots (C) in the gusset (1). Allow welds to cool completely and install bolt in clip to secure the harness moved in Step 2.
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   Illustration 27	g06015628
   Bottom view (1) Gusset (P) 25.4 mm (1.0 inch) (R) 63.5 mm (2.5 inch) (S) 27.9 mm (1.1 inch) (T) 66.0 mm (2.6 inch)

4. Refer to for dimensions on the placement of gusset (1) on to the platform. Weld gusset (1) to the platform using two slots (C).

Illustration 28	g06015700
Typical of completed right rear gusset installation

Left Rear Platform Repair

Illustration 29	g06015899
Rear platform

The procedure that follows will focus on the left rear platform area.

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Illustration 30	g06016255
(U) 25.4 mm (1.0 inch) (V) 63.5 mm (2.5 inch) (W) 27.9 mm (1.1 inch) (X) 66.0 mm (2.6 inch) (1) Gusset (4) Firewall post

1. Refer to Illustration 30 for dimensions for the placement of gusset (1). Gusset (1) will be welded to the platform frame near the left-hand firewall post (4). Weld gusset (1) to the platform using two slots (C).
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   Illustration 31	g06016326
   (AA) 27.9 mm (1.1 inch) (BB) 63.5 mm (2.5 inch) (CC) 25.4 mm (1.0 inch) (DD) 66.0 mm (2.6 inch) (1) Gusset

2. Refer to Illustration 31 for the dimensions for the placement of gusset (1) on to the platform. Gusset (1) will be welded to the platform frame above the battery box to the left of the gusset that was previously installed. Weld gusset (1) using two slots (C).

Illustration 32	g06016400

Bottom view of completed gusset installation.

Exhaust Handrail Repair Procedure for 994F and 994H Wheel Loaders

Illustration 33	g06016577

The procedure that follows will focus on the repair of the exhaust handrail.

Handrail Gusset Fabrication

Fabricate the gussets shown in Illustrations 34 and 35.

Gusset (1) and gusset (2) will be fabricated using 6.4 mm (0.25 inch) thick steel plate.

Illustration 34	g06017163
(1) Gusset

Illustration 35	g06018602
(2) Gusset

Handrail Gusset Installation Procedure

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Illustration 36	g06019142

1. Clamp gusset (2) so that the edges of gusset (2) are aligned with the center line of tubes (3) and (4). Clamp gusset (1) so that edges of gusset (1) are aligned with the center line of tubes (3) and (5).
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   Illustration 37	g06019060

2. Weld the gussets where indicated in Illustration 37.