Assembly Procedure for the 844H Wheel Dozer{7000, 7960} Caterpillar

Wheel Dozer:

844H (S/N: BTW1-UP)

Introduction

This publication contains the assembly procedure and the installation information 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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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering.

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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 in order to prevent pump cavitation.

Clean all of the surfaces before installing any parts.

ReferenceParts Manual, SEBP3849 Operation and Maintenance Manual, SEBU7893 Service Manual, RENR8830

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

Components and Weights

Illustration 1	g01267008

ROPS (1) ... 2250 kg (4960 lb)

Upper Half of Cab (2) ... 780 kg (1715 lb)

Blade (3) ... 5534 kg (12200 lb)

Main Chassis (4) ... 55790 kg (123,000 lb)

Each Tire and Rim Assembly (5) ... 2,993 kg (6600 lb)

Assembled machine with Tires and Blade ... 70815 kg (156120 lb)

Machine Dimensions

Illustration 2	g01267107

Illustration 3	g01267190

Dimension (A) ... 11419 mm (4450 inch)

Dimension (B) ... 5067 kg (11171 lb)

Dimension (C) ... 4152 mm (163 inch)

Dimension (D) ... 5419 mm (213 inch)

Preparation For Assembly

Table 1

Parts For Preparation For Assembly
Part Number	Part Description	Quantity
8T-4194	Bolts	12
5P-1076	Hard Washers	20
8T-4183	Bolts	8
194-5155	Exhaust Pipes	2
144-2641	Step	1
4E-8892	Handle	1
4E-8852	Handle	1

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Illustration 4	g00040011

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 suitable wood blocks between the trailer wheels.

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Illustration 5	g00887434

2. Position suitable wood blocks under the front of the trailer, as shown. Lower the front of the trailer onto the blocks, as shown. Disconnect the neck of the trailer from the base of the trailer and remove the truck.

3. The handholds, the exhaust stacks, and the lights will be located in a crate. Remove the crate from the truck.

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Illustration 6	g01250539

4. Install 144-2641 Step (4) with four 8T-4194 Bolts (3) and 5P-1076 Hard Washers .

5. Install 4E-8892 Handle (2) with four 8T-4194 Bolts (3) and 5P-1076 Hard Washers .

6. Install 4E-8852 Handle (1) with four 8T-4194 Bolts (3) and 5P-1076 Hard Washers .

7. Remove the covering from the mufflers.

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Illustration 7	g01244811

8. Install two 194-5155 Exhaust Pipes (5) to the mufflers with eight 8T-4183 Bolts (6) and 5P-1076 Hard Washers .

9. Uncover the bottom portion of the cab.

10. Remove all the chains and the fasteners that hold the machine to the trailer.

Installation of the Tires

Table 2

Parts For Installation of the Tires
Part Number	Part Description	Quantity
7X-0851	Nuts	192
6V-8237	Washers	192

Note: Check the air pressure in each tire before installation.

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Illustration 8	g00886892
Typical Example

1. Remove panel (1) that is located on the left rear of the machine. This panel must be removed in order to install the left rear tire.

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Illustration 9	g00878821
Front Tire

2. Attach a suitable hoist and lifting chains to tire and rim assembly (3), as shown.

3. Use the hoist in order to install tire and rim assembly (3).

4. Install 48 7X-0851 Nuts (2) and 6V-8237 Washers . Tighten nuts (2) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).

5. Repeat Steps 2 through 4 for each of the remaining tire and rim assemblies.

6. Install panel (1) to the left rear side of the machine.

Driving the Machine Off the Trailer

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Illustration 10	g00878846

1. Remove cotter pin (3) and pin (2) .

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Illustration 11	g00878847

2. Move steering frame lock (1) to the storage position, as shown.

3. Install pin (2) and cotter pin (3) .

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Illustration 12	g01250542

4. Turn the battery disconnect switch (4) to the ON position.

   Note: The battery disconnect switch (4) is located in a compartment on the rear bumper behind the left tire.

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Illustration 13	g00878841

5. Make sure that the yellow trigger switch (6) on the steering control handle is in the center detent position. This position is the neutral setting for the transmission.

   Note: The machine will not start unless the trigger switch is in the neutral position.

6. The steering lock lever (5) is located under the handle for the steering control. Move the steering lock lever (5) to the left of the steering console into the locked position.

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Illustration 14	g00878844

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Illustration 15	g00878845

Note: The engine key start switch (7) is located in the switch panel to the right of the seat. The parking brake control knob (8) is mounted in the bottom left corner of the dash.

7. Start the machine by moving the engine key start switch (7) past RUN to the START position.

   Note: The machine will perform a two second internal system check when the key is turned to the RUN position.

8. Move the steering lock lever (5) from the locked position by pulling the knob to the front of the steering control lever.

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Illustration 16	g00878849

9. Place your foot on the brake pedal.

10. Push the parking brake control knob (8) inward in order to release the parking brake.

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Illustration 17	g00878852

Note: The transmission defaults to third gear neutral. This position is indicated by the "3N" that is displayed on the dash panel.

11. Press the yellow downshift button (9) on the steering control handle twice, so that the gear indicator displays "1N". Place the transmission in forward by squeezing the steering control handle trigger switch (6) at the bottom. The gear indicator will change to "1F". Squeezing the top of the trigger switch will place the transmission in reverse, and the gear indicator will read "1R".

12. Carefully drive the machine off the trailer.

Installation of the Cab

Table 3

Parts For Installation of the Cab
Part Number	Part Description	Quantity
3E-6389	Dome Lamp Gp	1
3S-2093	Cable Strap	3
4E-1411	Terminal Bushing	1
4E-7204	Cover As	1
4E-7205	Seal	1
4E-9640	Handle	1
6V-8928	Coat Hook	1
7T-4306	Louver As	2
8T-5027	Nut	2
8Y-6352	Louver As	3
8Y-6388	Louver As	10
9U-1301	Handrail	1
9U-2330	Antenna Mount	2
9U-2331	Antenna As	1
9U-2332	Antenna As	1
9U-2670	Handrail	1
9X-8216	Cab Air Filter	1
123-8721	Duct	1
123-8722	Duct	1
123-8724	Insulation	1
123-8725	Insulation	1
138-8630	Duct	1
205-3076	Cover As	1
213-4262	Seal	1
251-4645	Rear Panel	1
251-4646	Headliner	1
251-6492	Strip	1
104-2091	Flat Head Screw	20
5L-6766	Plug	1
8T-4121	Hard Washer	28
8T-4133	Nut	4
8T-4183	Bolt	2
8T-4189	Bolt	6
8T-4191	Bolt	4
8T-4196	Bolt	20
8T-4223	Hard Washer	2
8T-4896	Hard Washer	6
9X-1046	Screw	3
9X-2042	Screw	3
9X-2045	Screw	3
090-4808	Seal	590 cm (232.28 inch)
103-2543	Seal	193 cm (75.98 inch)

1. Turn off the battery disconnect switch.

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Illustration 18	g01248253

2. Verify that 4E-6510 Seal (A) is located on the bottom portion of the cab. Verify that 4E-6509 Seal (B) is located on the bottom portion of the cab. Verify that two 256-2454 Seals (C) are located on the bottom portion of the cab.

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Illustration 19	g00888746

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Illustration 20	g00889805

3. Remove two nuts (1) and the washers from each side of the cab.

4. Install 9U-2670 Handhold (2) to the right side of the cab with two nuts (1) and the washers.

5. Install 9U-1301 Handhold (3) to the left side of the cab with two nuts (1) and the washers.

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Illustration 21	g00892110

6. Route wires (4) and (5) for the antenna toward the front of the cab for later connection to the ROPS.

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Illustration 22	g01248182

7. Remove the right side instrument panel prior to installing the cab. Refer to Illustration 22.

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Illustration 23	g01258563
Typical Example

8. Attach a suitable hoist and lifting chains to the three lifting points on cab (6). Use the hoist in order to lift the top portion of cab (6) into position over the bottom portion of the cab. Slowly lower the top of the cab into position. There are three dowel pins on the lower portion of the cab. The dowels are used to line up the top portion of the cab with the bottom portion of the cab.

   Note: The top portion of the cab will need to be guided into position onto the bottom portion of the cab.

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Illustration 24	g00878949

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Illustration 25	g01258566

9. Secure the top portion of the cab to the bottom portion of the cab with 20 8T-4136 Bolts (7) and 8T-4223 Hard Washers .

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Illustration 26	g01259714

10. Connect wiring harness (8) between the top portion of the cab and the bottom portion of the cab.

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Illustration 27	g01259719

11. Connect tube (9) for the washer fluid to the front wiper motor (10) .

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Illustration 28	g00886996

12. Connect electrical connector (11) that is located near the right rear corner of the cab.

13. Connect hose assembly (12) that is located near the right rear corner of the cab.

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Illustration 29	g00878966

14. Install 123-8725 Insulation (13) over the right rear inside post of the cab.

15. Install two 7T-4306 Louver As (14) into insulation (13) .

    Note: The fabric will have to be cut over the openings in the louver in order to install louver assemblies (14) .

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Illustration 30	g00887001

16. Install 4E-7205 Seal (16) around the bottom of 123-8722 Duct (15) prior to installing the duct.

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Illustration 31	g00878968

17. Install duct (15) behind the seat. Secure duct (15) with six 8T-4189 Bolts (17) and 8T-4222 Washers .

18. Install 103-2543 Seal (18) on duct (15) on the contact surface for the air filter.

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Illustration 32	g00887010

19. Install 9X-8216 Air Filter (19) in the opening of duct (15) .

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Illustration 33	g00878970

20. Install 4E-7204 Cover As (22) with two 7K-3262 Screws (21) and 2R-2376 Washers .

21. Install two 8T-5027 Nuts (20) and 9X-2045 Screws in order to plug the unused holes.

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Illustration 34	g00887017

22. Install 123-8724 Insulation (24) over the left rear inside post of the cab.

23. Install 6V-8928 Coat Hook (25) with one 9X-2042 Screw (23) .

24. Install 3E-6389 Dome Lamp (26) onto insulation (24) with three 9X-1046 Screws .

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Illustration 35	g01258571

25. Install 090-4808 Seal (27) around the lower joint of 123-8721 Duct (28). Install seal (27) around the upper joint of duct (28) .

26. Install duct (28) .

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Illustration 36	g00889388

27. Install 213-4262 Seal (29) on the mating surface of the lower duct that is located on the right-hand side of the cab.

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Illustration 37	g00900567

28. Verify that the seals are in place on 138-8630 Duct .

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Illustration 38	g00878983

29. Install 138-8630 Duct (32) .

30. Install four 8T-4196 Bolts (30) and 8T-4121 Hard Washers .

31. Install two 8T-5027 Nuts (31) and 9X-2045 Screws on duct (32) in order to plug the unused holes.

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Illustration 39	g00879004

32. Install 4E-9640 Handle (35) .

33. Install two 8T-4183 Bolts (36) and 8T-4223 Hard Washers .

34. Install three 8Y-6352 Louver As (33) .

35. Install ten 8Y-6388 Louver As (34) with 20 104-2091 Flat Head Screws .

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Illustration 40	g00879087

36. Install 205-3076 Cover As (38) with three 9X-2042 Screws (37) .

37. If the machine is not equipped with a payload monitor, then install 5L-6766 Plug (39) .

38. Refer to Steps 39 through 44 if the machine is equipped with a payload monitor. If you do not have a payload monitor, continue with Step 45.

39. Remove three screws (37) from cover assembly (38) .

40. Replace 5L-6766 Plug (39) with a 3E-6754 Grommet .

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Illustration 41	g00888835

41. Connect the payload monitor to the cab post with two 8T-4195 Bolts (40) and 8T-4121 Hard Washers .

42. Route wiring harness (41) through the grommet in cover assembly (38) .

43. Connect wiring harness (41) to the main wiring harness for the cab that is located under the instrument panel.

44. Install cover assembly (38) with three screws (37) .

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Illustration 42	g01248187

45. Install four 8T-4136 Bolts (42) and 8T-4121 Hard Washers .

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Illustration 43	g01248189

46. Remove three bolts (43), the washers, and channel (44) .

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Illustration 44	g01258644

47. Connect tube assemblies (45) and (46) .

48. Connect electrical connector (47) .

49. Install 8T-4191 Bolt (48), 8T-4121 Hard Washer , 4K-8864 Clip , 5P-9297 Clip , and 7N-3718 Clip .

50. Install channel (44), three bolts (43), and the washers.

51. Refer to Step 52 and Step 53 if the machine is equipped with the 267-8836 Camera . If the machine is not equipped with the 267-8836 Camera , continue to ""Installation of the ROPS" ".

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Illustration 45	g01248222

52. Mount 251-4157 Display Module Gp (49) on upper right door post.

53. Connect the electrical connector for the camera to the rear of the front display.

Note: Refer to Parts Manual, SEBP3850, "990H Wheel Loader" for details of the 252-9529 Camera Mounting Gp and 267-8837 Camera Wiring Gp .

Installation of Product Link

Note: Install the product link prior to the installation of the ROPS on the machine.

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Illustration 46	g01861537
Bottom side of ROPS canopy (1) 263-9088 Communication Radio Gp (2) 253-2585 Plate Assembly (3) 8T-4138 Bolt (4) 9X-8256 Washer

1. Attach 263-9088 Communication Electronic Control Module (1) to 253-2585 Plate Assembly (2). Use four 8T-4138 Bolts (3) and four 9X-8256 Washers (4) in order to connect the module to the plate. Tighten the bolts to a torque of 3.5 ± 1.0 N·m (30 ± 9 lb in).

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 in order to mount the plate to the canopy. Connect the ROPS wiring to the communication ECM.

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Illustration 47	g01861554
Left side of ROPS canopy (5) 270-8544 Bracket Assembly (6) 8T-4136 Bolt (7) 8T-4121 Hard Washer (8) 310-2391 Antenna Assembly (9) 9X-6772 Cable Strap

3. Attach 270-8544 Bracket Assembly (5) to the left side of the ROPS canopy. Use two 8T-4137 Bolts and two 8T-4121 Hard Washers in order to attach the bracket.

4. Attach 310-2391 Antenna Assembly (8) to the 270-8544 Bracket Assembly . Tighten the nut on the antenna to 5.0 ± 0.5 N·m (44 ± 4 lb in). Use one 9X-6772 Cable Strap (9) in order to strap the antenna cable to the underside of the bracket. Use an additional cable strap in order to strap the cable to the link on the left side of the ROPS.

5. Attach the antenna cable to the communication ECM. Use cable straps in order to strap the cable to the underside of the ROPS canopy.

Installation of the ROPS

Table 4

Parts For Installation of the ROPS
Part Number	Part Description	Quantity
8C-3222	Bolts (1)	3
9X-8399	Washers (1)	3
138-7576	Link Brackets (1)	3
8C-3236	Bolts	36
3S-7023	Washers	36
092-3206	Spacers	8
196-5003	Plate	1
212-8787	Cover As	1
212-8788	Cover As	1
221-7090	Guard As	1
221-7091	Guard As	1
5P-1076	Washers	8
7X-7729	Washers	6
8T-4121	Washers	8
8T-4137	Bolt	6
8T-4139	Bolts	2
8T-4179	Bolts	6
8T-6466	Bolts	8

( 1 )

Required tooling for installation of the ROPS

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Illustration 48	g01248439
Top View of the Cab and Platform

1. Remove four bolts, the washers, and the spacers from platform (1). Remove platform (1). Remove four bolts, the washers, and the spacers from platform (2). Remove platform (2) .

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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Illustration 49	g01248443

2. Disconnect hoses (3) for the autolube system.

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Illustration 50	g01259344

3. Install three 8C-3222 Bolts , three 9X-8399 Washers , and three 138-7576 Link Brackets (4) to the top of the rollover protection structure (5) .

4. Attach a suitable hoist and lifting chains to link brackets (4) .

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Illustration 51	g01259419
Typical Example

Note: The mating surfaces of the rollover protection structure and the frame must be clean, dry, and free of paint at the time of installation.

5. Use the hoist in order to install rollover protection structure (5) .

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Illustration 52	g01259376

6. Install 18 8C-3236 Bolts (6) and 3S-7023 Washers to each side of the rollover protection structure (5). The torque for bolts (6) is 1600 ± 200 N·m (1180 ± 150 lb ft).

7. Connect hoses (3) for the autolube system.

8. Install platform (2), four bolts, the washers, and the spacers.

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Illustration 53	g01259425

9. Install 221-7091 Guard As (10) with two 8T-4179 Bolts (7), two 8T-4139 Bolts and four 5P-1076 Hard Washers .

10. Install 196-5003 Plate (9) with six 8T-4137 Bolts (8) and six 7X-7729 Washers .

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Illustration 54	g01259437

11. Install 221-7090 Guard As (11) with four 8T-4179 Bolts (12) and four 5P-1076 Washers .

12. Install platform (1), four bolts, the washers, and the spacers.

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Illustration 55	g01259440

13. Install 212-8787 Cover As (13) with four 8T-6466 Bolts (15), 8T-4121 Hard Washers , and 092-3206 Spacers .

14. Install 212-8788 Cover As (14) with four 8T-6466 Bolts (15), 8T-4121 Hard Washers , and 092-3206 Spacers .

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Illustration 56	g01259381

15. If the machine is equipped with an automatic lubrication system, connect the hose assemblies and the wiring harness.

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Illustration 57	g01259570
Location of films on the left side of the ROPS

16. Place the 219-0305 Film and the 237-6245 Film on the left side of the ROPS. These films will be inside a plastic bag that is attached to the STIC steering lever in the cab. Attach these films to the left side of the ROPS canopy. The films should be 12 mm (0.47 inch) from the bottom edge of the canopy and 155 mm (6.1 inch) from the rear edge of the canopy.

Installation of the Radio and the Antennas

Table 5

Parts For Installation of the Antennas
Part Number	Part Description	Quantity
3S-2093	Cable Straps	3
9U-2330	Mounts	2
9U-2331	Antenna	1
9U-2332	Antenna	1

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Illustration 58	g00879361

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Illustration 59	g00878322
Connector for radio

1. If the machine is equipped with a Caterpillar radio, mount the radio in the upper right panel (1). Use the eight-pin connector that is provided.

   Note: If another brand of radio is being installed, the connection may be modified in order to match the radio. The connector is wired, as shown.

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   Table 6

   Pin Identification for Radio Connector
   Pin	Wire Number	Color	Function
   1	509	White	Left Speaker
   2	508	Purple	Left Speaker
   3	200	Black	Ground
   4	120	Yellow	24 V B+
   5	513	Pink	Memory
   6	135	Blue	12 V B+
   7	512	Green	Right Speaker
   8	511	Brown	Right Speaker

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Illustration 60	g00879893

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Illustration 61	g00892184
Front View

2. Install two 9U-2330 Mounts (5) and (6) .

3. Connect shorter white wire (2) for the radio to mount (5), as shown.

4. Connect longer black wire (4) for the CB to mount (6), as shown.

5. Secure wires (2) and (4) to ROPS (3) along the existing wire harness with three 3S-2093 Cable Straps .

6. Install 9U-2331 Antenna As (7) to mount (5) .

7. Install 9U-2332 Antenna As (8) to mount (6) .

Installation of the Handholds, Lights, and Mirrors

Table 7

Parts for Installation of the Handholds, Lights, and Mirrors
Quantity	Part Number	Description
10	096-4883	Locknut
2	325-7350	Handrail As
1	325-7353	Gate As
4	126-7222	Angle
2	144-2641	Step Gp
4	147-0319	Flood Lamp Gp
1	164-1990	Bracket As
1	164-1991	Bracket As
4	174-7594	Bracket
1	205-3159	Film
1	9X2557	Film
1	325-7362	Handrail As
1	300-6379	Handrail As
2	300-6344	Handle
2	300-6343	Handle
1	4E-9625	Bracket As
8	5C-7261	Nut
84	5P-1076	Hard Washer
2	5P-6879	Mirror
4	6G-8829	Clamp
5	6V-3822	Bolt
5	6V-5839	Washer
4	6V-7744	Locknut
4	7I-3722	Clip
1	325-7355	Ladder As
1	325-7361	Handrail As
2	7U-1903	Support
18	7X-7729	Washer
34	8T-4121	Hard Washer
2	8T-4133	Nut
12	8T-4136	Bolt
8	8T-4137	Bolt
6	8T-4139	Bolt
41	8T-4183	Bolt
6	8T-4186	Bolt
8	8T-4194	Bolt
10	8T-4195	Bolt
12	8T-4223	Hard Washer
12	8T-4224	Hard Washer
16	8T-4956	Bolt
4	8T-6869	Bolt
1	9U-0833	Bracket As
1	325-7360	Handrail As
1	325-7359	Handrail As
1	9U-3663	Plate As
1	325-7363	Handrail As
2	323-3751	Step As
2	323-3748	Belts
4	4V-9803	Plates
8	8T-4184	Bolts
8	6V-7687	Locknuts
4	325-7233	Bracket As
4	5P-2228	Bolts
4	8F-6437	Washers
2	127-0366	Spacers
2	161-3357	Spacers
2	323-3747	Brackets
2	8T-6466	Bolts
2	248-0102	U-Bolts
1	300-4511	Latch As
1	323-3749	Bracket
2	323-3746	Bracket
1	325-7369	Guard
1	325-7382	Guard
1	325-7368	Guard
1	325-7367	Guard
34	8T-4192	Bolt
2	325-7381	Guard
1	325-7366	Guard
1	237-7952	Sheet As
1	250-4912	Platform As
1	250-4913	Platform As
1	325-7356	Handrail As
1	325-7365	Handrail As
1	325-7364	Handrail As
4	115-3580	Plate
8	5P-7468	Clip
8	5P-7469	Clip
8	6V-1874	Grommet
8	8T-4244	Nut
1	325-7383	Guard
1	333-9681	Guard
1	333-9682	Guard
8	8T-2561	Bolt

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Illustration 62	g01873873
Right side of machine

1. Install 325-7355 Ladder As (5) with four 8T-4139 Bolts (40) and four 5P-1076 Hard Washers (6) .

2. Install 325-7361 Handrail As (4) with six 8T-4183 Bolts (16) and six 5P-1076 Hard Washers (6) .

3. Install 325-7360 Handrail As (2) with seven 8T-4183 Bolts (16) and seven 5P-1076 Hard Washers (6) .

4. Install 325-7350 Handrail As (15) with four 8T-4183 Bolts (16) and four 5P-1076 Hard Washers (6) .

5. Install 300-6379 Handrail As (1) with eight 8T-4956 Bolts (23) and eight 8T-4223 Hard Washers (44) .

6. Install 325-7363 Handrail As (46) with six 8T-4183 Bolts (16) and six 5P-1076 Hard Washers (6) .

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Illustration 63	g01873954
Gate assembly and step assembly

7. Install 325-7353 Gate Assembly (3). Refer to Illustration 62.

8. Secure the handrail assembly with two 323-3747 Brackets (57) with four 8T-4195 Bolts (14) and four 8T-4121 Hard Washer (28) to 325-7360 Handrail Assembly (2). Refer to Illustration 63.

9. Secure two 323-3746 Brackets (62) with four 8T-4195 Bolts (14) and four 8T-4121 Hard Washer (28) to 325-7353 Gate Assembly (3).

10. Secure 323-3749 Bracket (61) with two 8T-4195 Bolts (14) and two 8T-4121 Hard Washers (28) to 325-7353 Gate Assembly (3) .

11. Secure gate assembly with two 8T-6466 Bolts (58), two 127-0366 Spacers (55), two 161-3357 Spacers (56), four 7X-7729 Washers (19), and two 096-4883 Locknuts (26) .

12. Confirm easy outward opening of the gate.

13. Secure the 300-4511 Latch Assembly (60) to the 325-7361 Handrail Assembly (4) with two 248-0102 U-Bolts (59), four 8T-4224 Hard Washers (45), and four 5C-7261 Nuts (8). The latch assembly must be assembled in a way that allows the latch rod to go through the hole of the 323-3749 Bracket (61) that is attached to the gate assembly. Refer to Illustration 63.

14. Install two 323-3751 Step As (47) with two 323-3748 Belts (48), four 4V-9803 Plates (49), eight 8T-4184 Bolts (50), and eight 6V-7687 Locknuts (51). Refer to illustration 62.

15. Install four 325-7233 Bracket As (52), four 5P-2228 Bolts (53), four 8F-6437 Washers (54), and four 8T-4223 Hard Washers (44) .

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Illustration 64	g01874015
Right rear of machine

16. Install 144-2641 Step (12) with four 8T-4194 Bolts (7) and four 5P-1076 Hard Washers (6) .

17. Install 300-6344 Handle (11) with four 8T-4194 Bolts (7) and four 5P-1076 Hard Washers (6) .

18. Install 300-6343 Handle (10) with four 8T-4194 Bolts (7) and four 5P-1076 Hard Washers (6) .

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Illustration 65	g01874053
Left side of machine

19. Install 220-6064 Handrail As (17) with six 8T-4183 Bolts (16) and six 5P-1076 Hard Washers (6) .

20. Install 325-7350 Handrail As (15) with four 8T-4183 Bolts (16) and four 5P-1076 Hard Washers (6) .

21. Install 325-7359 Handrail As (13) with eight 8T-4183 Bolts (16) and eight 5P-1076 Hard Washers (6) .

22. Install 8T-4192 Bolt (67), 7X-7729 Washer (19), and 8T-4133 Nut (39) in order to secure 122-5967 Handrail As (15) to handrail assembly (13) .

23. Install 8T-4192 Bolt (67), 7X-7729 Washer (19), and 8T-4133 Nut (39) in order to secure 122-5967 Handrail As (15) to handrail assembly (17) .

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Illustration 66	g01874133
Right side guard for toes

24. Install 325-7381 Guard Plate (66) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

25. Install 325-7368 Guard Plate (65) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

26. Install 325-7382 Guard Plate (64) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

27. Install 325-7369 Guard Plate (63) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

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Illustration 67	g01874173
Left side guard for toes

28. Install 325-7381 Guard Plate (66) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

29. Install 325-7367 Guard Plate (68) with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

30. Install 325-7366 Guard Plate (69) with four 8T-4192 Bolts (67), four 5P-1076 Hard Washers (6), two 8T-4139 Bolts (40), and two 5P-1076 Hard Washers (6) .

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Illustration 68	g01875036
Walkway for the cab

31. Assemble 237-7952 Sheet Assembly (70) with 250-4912 Platform (71) and 250-4913 Platform (72). Secure platforms with eight 8T-4195 Bolts (14) and eight 7X-7729 Washers (19) .

32. Install 325-7356 Handrail Assembly (73). Secure handrail assembly with four 8T-4139 Bolts (40) and four 8T-4223 Hard Washers (44) .

33. Install 325-7365 Handrail Assembly (74). Secure handrail assembly with four 8T-4139 Bolts (40) and four 8T-4223 Hard Washers (44) .

34. Install 325-7364 Handrail Assembly (75). Secure handrail assembly with four 8T-4139 Bolts (40) and four 8T-4223 Hard Washers (44) .

35. Install 325-7383 Guard Plate (81). Secure guard plate with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

36. Install 333-9681 Guard Plate (82). Secure guard plate with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

37. Install 333-9682 Guard Plate (83). Secure guard plate with four 8T-4192 Bolts (67) and four 5P-1076 Hard Washers (6) .

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Illustration 69	g01875194
Fasteners for the walkway

38. Install two 6V-1874 Grommets (79), two 5P-7469 Clips (78), two 5P-7468 Clips (77) and a 115-3580 Plate (76) to each handrail. Refer to Illustration 69.

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Illustration 70	g01874193
Front view of cab

39. Install 164-1990 Bracket As (22) to the right side of the cab with four 8T-4956 Bolts (23) and four 5P-1076 Hard Washers (6) .

40. Assemble four 8T-4195 Bolts and four 8T-2561 Hard Washers to the right-hand walkway. Assemble four 8T-4195 Bolts and four 8T-2561 Hard Washers to the left-hand walkway. Secure the walkway to the front of the cab.

41. Install 164-1991 Bracket As (24) to the left side of the cab with four 8T-4956 Bolts (23) and four 5P-1076 Hard Washers (6) .

42. Attach two 126-7222 Angles (20) to bracket assembly (22) with two 8T-4136 Bolts (18) and two 7X-7729 Washers (19) .

43. Attach two 126-7222 Angles (20) to bracket assembly (24) with two 8T-4136 Bolts (18) and two 7X-7729 Washers (19) .

Note: Perform the following step in order to attach 5P-6879 Mirror (25) to the right side and the left side of the cab.

44. Attach each mirror (25) to angle (20) with two 8T-4136 Bolts (18), four 7X-7729 Washers (19), and two 6V-7744 Locknuts (21) .

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Illustration 71	g01874233
Right-hand side of cab

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Illustration 72	g01874234
Left-hand side of cab

45. Install 7U-1903 Support (30) with two 8T-4136 Bolts (18), four 8T-4121 Washers (28), two 096-4883 Nuts (26), and two 7I-3722 Clips (27) to the right side handhold.

46. Install 5P-6879 Mirror (25) to support (30) with two 8T-4186 Bolts (29), four 8T-4121 Washers (28), two 096-4883 Nuts (26), and two 6G-8829 Clamps (31) .

47. Repeat Steps 45 and 46 for the left side mirror.

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Illustration 73	g01874253
Rear of cab

48. Attach 205-3159 Film (34) to the upper rear of the canopy.

49. Attach 9U-0833 Bracket (32) to the left rear side of the cab with two 8T-4137 Bolts (38) and two 8T-4121 Hard Washers (28) .

50. Attach 4E-9625 Bracket (33) to the right rear side of the cab with two 8T-4137 Bolts (38) and two 8T-4121 Hard Washers (28) .

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Illustration 74	g01874273

51. Attach 147-0319 Flood Lamp (36) to 174-7594 Bracket (35) with 8T-6869 Bolt (37), two 8T-4224 Hard Washers (45), and 5C-7261 Nut (8) .

52. Repeat Step 51 for the other rear canopy light and for the two front canopy lights.

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Illustration 75	g01874277
Rear of cab for light mounts

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Illustration 76	g01874279

53. Attach one flood lamp (36) to bracket (32) with 8T-4137 Bolt (38) and 8T-4121 Hard Washer (28) .

54. Attach one flood lamp (36) to bracket (33) with 8T-4137 Bolt (38) and 8T-4121 Hard Washer (28) .

55. Plug each harness assembly (39) into the back of both rear flood lamps (36) for the canopy.

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Illustration 77	g01874869
Front right flood lamp

56. Attach one flood lamp (36) to the right front of the canopy with 8T-4137 Bolt (38) and 8T-4121 Hard Washer (28) .

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Illustration 78	g01874865
Left front flood lamp

57. Attach one flood lamp (36) to the left front of the canopy with 8T-4137 Bolt (38) and 8T-4121 Hard Washer (28) .

58. Plug each harness assembly (39) into the back of both front flood lamps (36) for the canopy.

    Note: If the machine is equipped with the 234-7887 Stop and Flood Lighting Ar , mount the 266-7726 Flood Lighting Gp to the front of the ROPS. Mount the 224-9280 Stop and Tail Lighting Group to the radiator guard. Refer to Parts Manual, SEBP3850, "990H Wheel Loader" for details on these parts.

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Illustration 79	g01874873
Front of cab

59. Install 9U-3663 Plate As (42) to the front of the canopy with five 6V-3822 Bolts (41) and 6V-5839 Washers (9) .

60. Install 9X-2557 Film (43) to plate assembly (42) .

Installation of the Push Beam to the Front Frame

1. Remove the square bars and remove the fill plates if the square bars and the fill plates are attached to the machine. Remove the square bars and the fill plates in order to install the 153-9485 Push Beam .

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Illustration 80	g00409079
The top view of the front frame (1) 153-9485 Push Beam . (2) Front Frame. (3) Hitch.

Note: Ensure that you have a lifting device that can lift beam (1). The weight of the beam is 5450 kg (12000 lb).

2. Use an appropriate lifting device to position the beam at the side of front frame (2). Pull the beam through the cavity that is provided. The cavity is located behind the front wheels.

   Note: If the beam is oversize, areas of the inner front surface of the cavity may be trimmed. If the beam is oversize, areas of the inner top surface of the cavity may be trimmed. Do not trim the inner bottom surface of the cavity. Do not trim the inner rear surface of the cavity.

3. Position beam (1) so that an equal amount of the beam is protruding from either side of the front frame.

4. Ensure that the beam is pushed back against the inner rear wall of the cavity.

5. Clean the area near the weld joint.

6. Preheat the area of the frame around the beam to 125° ± 25°C (258° ± 45°F). Preheating should extend 75 mm (3.0 inch) from the joints.

   Note: Temperature readings should be taken 75 mm (3.0 inch) from each joint.

7. Preheat the beam to 50°C (120°F). The preheater should extend 75 mm (3.0 inch) from the joints.

   Note: Maintain the temperature during welding in order to minimize embrittlement.

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   Table 8

   Mounting locations
   Item	Qty	Part Number	Description
   8	2	197-8591	Bar
   9	2	197-8588	Bar
   10	2	197-8595	Bar
   11	1	197-8587	Bar
   12	2	197-8586	Bar
   13	4	197-8592	Bar
   14	4	197-8593	Bar
   15	2	197-8594	Bar
   16	1	197-8590	Bar
   17	2	195-9953	Plate

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Illustration 81	g01272341
Refer to Table 8 for the parts list.

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Illustration 82	g01272342
Refer to Table 8 for the parts list.

8. Weld the bars with a 20 mm (0.79 inch) fillet weld and 1.5 mm (0.6 inch) penetration.

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Illustration 83	g00409087

9. Install square bars (5) and install fill plates (4) when the beam will be welded onto the frame.

   Note: The size of the weld bead should not exceed 8.0 mm (0.32 inch).

   Note: All finished welds should be 12.0 mm (0.50 inch) wide.

   Note: The maximum interpass temperature should not exceed 200°C (392°F).

   Note: Welding wire must be of a low hydrogen electrode.

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Illustration 84	g00409088

10. Weld three fillet welds (6) in order to attach the beam to the square bar and the square bar to the frame. Completely weld every square bar and fill plate to the beam.

    Note: Stich welding (7) on the top of the three fillet welds is optional.

11. Paint the welded areas of the beam and frame in order to prevent corrosion.

12. Repeat Steps 5 through 12 in order to weld the other side of the beam to the frame.

Installation of the Trunnion Assembly to the Push Beam

1. Remove the shipping cover from the end of the push arm.

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Illustration 85	g00409161

2. Place two guide pins (3) in two of the bolt holes in push arm (2) .

3. Install trunnion assembly (1) onto the guide pins.

4. Install 12 7X-0404 Bolts (4).

5. Replace the two guide pins with two 7X-0404 Bolts (4) .

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Illustration 86	g00409164

6. Tighten 14 7X-0404 Bolts (4) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).

7. Repeat Steps 1 through 6 in order to install the remaining trunnion assembly to the opposite end of the beam.

Installation of the Push Arm to the Blade

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Illustration 87	g01272133

1. Install 8E-6758 Connector (3) with 4T-7534 Pin (1), 6J-5179 Retainer (4), and two 7X-0380 Bolts (2) on each side of the blade. Tighten bolts (2) to a torque of 700 ± 90 N·m (520 ± 65 lb ft).

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Illustration 88	g00407176

2. Install stabilizer link (5) to the blade assembly by using four 7X-0395 Bolts (8), four 7X-0449 Nuts (7), and 4T-8087 Bearing Cap (6). Do not use shims. Tighten 7X-0395 Bolts until the bolts are snug. Maintain an equal distance on both sides of the cap.

3. Insert an equal amount of 4T-9470 Shims to each of the spaces. This procedure should allow the assembly to move on the trunnion freely. Also, the assembly should move only within the specified clearance. The specified clearance between the trunnion and the stabilizer link group is 0.50 ± 0.25 mm (0.020 ± 0.010 inch).

4. Tighten 7X-0395 Bolts (4) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

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Illustration 89	g00407480

5. On each side of the blade, install a push arm with 4T-7534 Pin (11). Secure the pin with 6J-5179 Retainer (9) and two 7X-0380 Bolts (10). Tighten bolts (10) to a torque of 700 ± 90 N·m (520 ± 65 lb ft).

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Illustration 90	g00407482

6. Install 6E-4836 Tilt Cylinder (12) to the right side of the blade with 1U-2472 Pin (15). Secure the pin with 6J-5179 Retainer (13), and two 7X-0380 Bolts (14). Tighten bolts (14) to a torque of 700 ± 90 N·m (520 ± 65 lb ft).

7. Repeat Step 6 in order to install 6E-4835 Tilt Cylinder to the left side of the blade.

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Illustration 91	g00407704

8. Use two 1P-4576 Flanges , one 4J-5267 O-Ring Seal , four 5S-7382 Bolts , and four 5M-2894 Washers for each connection in Steps 9 through 12.

9. Connect the 45° end of 152-7752 Hose (18) to tube assembly (16) .

10. Connect the 45° end of 152-7751 Hose (20) to tube assembly (21) .

11. Connect the 45° end of 152-7754 Hose (19) to tube assembly (17) .

12. Connect the 45° end of 152-7753 Hose (23) to tube assembly (22) .

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Illustration 92	g00407750

13. Connect four 152-7755 Hoses (25) to manifold (24). Use two 1P-4576 Flanges , one 4J-5267 O-Ring Seal , four 5S-7382 Bolts , and four 5M-2894 Washers for each connection.

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Illustration 93	g00407800

14. Connect the 90° end of 152-7752 Hose (16) to port (27) on the piston end of the left-hand tilt cylinder.

15. Connect the 90° end of 152-7751 Hose (20) to port (26) on the rod end of the left side tilt cylinder.

16. Repeat Step 14 for 152-7754 Hose (19) on the right side tilt cylinder.

17. Repeat Step 15 for 152-7753 Hose (23) on the right side tilt cylinder.

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Illustration 94	g00407866

18. Install one 154-1923 Guard (28) with four 7X-0380 Bolts (29) and four 8C-6913 Hard Washers to each tilt cylinder. Tighten bolts (29) to a torque of 700 ± 90 N·m (520 ± 65 lb ft).

Installation of the Push Arm and the Blade onto the Machine

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Illustration 95	g00405021

1. The machine should be moved into position between push arms (1) and the blade assembly. Move the machine slowly. Continue to move the machine ahead until the push arms engage with the trunnion (2) .

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Illustration 96	g00405023

2. Install one 7T-3560 Bearing Cap (3) and install two 1D-4649 Bolts (4) without shims onto push arm (1). Tighten 1D-4649 Bolts (4) until the bolts are snug. Maintain an equal distance on both sides of the cap.

3. Insert an equal amount of 7T-2425 Shims between the bearing cap and the push arm assembly.

4. Add one additional 7T-2425 Shim to each of the spaces. This procedure should allow the assembly to move on the trunnion freely. The assembly should move within the specified clearance. The specified clearance between the trunnion and the push arm assembly is 0.50 ± 0.25 mm (0.020 ± 0.010 inch).

5. Tighten two 1D-4649 Bolts (4) to a torque of 1800 ± 200 N·m (1325.0 ± 145.0 lb ft).

6. Repeat Steps 2 through 5 in order to install the cap, the bolts, and the shims onto the opposite side of the machine.

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Illustration 97	g00405031

7. Connect four 152-7755 Hoses (5). Use two 1P-4576 Flanges , one 4J-5267 O-Ring Seal , four 5S-7382 Bolts , and four 5M-2894 Washers for each connection.

   Note: Do not cross the hoses.

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Illustration 98	g00405138

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Illustration 99	g00405149

8. Attach a suitable lifting sling and a hoist to stabilizer link group (6) .

9. Raise the disconnected end of stabilizer link group (6) to trunnion (10). Trunnion (10) is on the front of the front frame.

10. Start the machine. Carefully turn the machine to the right until stabilizer link group (6) is engaged with trunnion (10). Stop the machine.

11. Install 4T-8087 Bearing Cap (7) without shims. Install the cap with four 7X-0395 Bolts (8) and four 7X-0449 Nuts (9). Tighten 7X-0395 Bolts until the bolts are snug. Maintain an equal distance on both sides of the cap.

12. Insert an equal amount of 4T-9470 Shims to each of the spaces. This procedure should allow the assembly to move on the trunnion freely. The assembly should move within the specified clearance. The specified clearance between the trunnion and the stabilizer link group is 0.50 ± 0.25 mm (0.020 ± 0.010 inch).

13. Tighten 7X-0395 Bolts (8) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

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Illustration 100	g00405156

14. Start the machine. Extend the lift cylinder rods to the trunnions that are on the back of the blade. Stop the machine.

15. Install bolts (11) and cap (12) without shims. Tighten the bolts until the bolts are snug. Maintain an equal distance on both sides of the cap.

16. Insert an equal number of shims in the spaces between the bearing cap and the cylinder assembly.

17. Add one additional shim to each of the spaces. This procedure should allow the assembly to move on the trunnion freely. The assembly should move within the specified clearance. The specified clearance between the trunnion and the rod assembly is 0.50 ± 0.25 mm (0.020 ± 0.010 inch).

18. Tighten bolts (11) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

19. Repeat Steps 15 through 18 in order to install the bolts, the cap, and the shims onto the remaining lift cylinder.

Testing and Adjusting Procedure for the Automatic Lubrication Pressure

Illustration 101	g01283996

Before the lubrication system is tested, the supply lines and the supply lines (feed) must be primed with grease.

Test Procedure

1. Read pressures at low idle.

   1. Initiate a lube cycle at low idle.

   2. During the lube cycle, watch pressure gauge (7) that is located at the output on the tank.

   3. Wait until the grease pressure stabilizes. Record the pressure on the gauge. The stabilized maximum pressure will only stay for a few seconds.

2. If necessary, adjust the pressure.

   1. Record the pressure at the tank during low idle. If the pressure is not within the range of 20000 kPa (2900 psi) to 24100 kPa (3500 psi), adjust hydraulic pressure regulator (8).

   2. Turn the screw clockwise in order to increase the pressure. Turn the screw counterclockwise in order to reduce the pressure.

3. Record the pressures.

   1. The operator can set the maximum fan speed by using ET. Refer to Service Manual, RENR5397, "Large Wheel Loader Autolube System".

Machine Testing and Adjusting

Refer to the following procedures in order to ensure that the machine is functioning properly:

• Testing and Adjusting, RENR8817, "990H Wheel Loader and 844H Wheel Dozer Steering System", "Steering System Pressure (High Pressure Stall) - Test and Adjust"

• Testing and Adjusting, RENR8837, "844H Wheel Dozer Hydraulic System", "Torque Converter Stall and Implement Pump Double Stall - Test"

• Testing and Adjusting, RENR8837, "844H Wheel Dozer Hydraulic System", "Manifold and Relief Valve (Main) - Test"

• Testing and Adjusting, RENR8837, "844H Wheel Dozer Hydraulic System", "Pilot System Pressure - Test"

• Testing and Adjusting, RENR8820, "990H Wheel Loader and 844H Wheel Dozer Braking System", "Service Brake System Pressure - Test"

• Testing and Adjusting, RENR8820, "990H Wheel Loader and 844H Wheel Dozer Braking System", "Relief Valve (Brake System Backup) - Test and Adjust"

• Testing and Adjusting, RENR8820, "990H Wheel Loader and 844H Wheel Dozer Braking System", "Brake Accumulator - Test and Charge"

• Testing and Adjusting, RENR8820, "990H Wheel Loader and 844H Wheel Dozer Braking System", "Service Brakes - Test"

• Testing and Adjusting, RENR8811, "990H Wheel Loader and 844H Wheel Dozer Power Train", "Torque Converter Impeller Clutch Pressure - Test"

• Testing and Adjusting, RENR8811, "990H Wheel Loader and 844H Wheel Dozer Power Train", "Torque Converter Lockup Clutch Pressure - Test"

• Testing and Adjusting, RENR8811, "990H Wheel Loader and 844H Wheel Dozer Power Train", "Transmission Pressures - Test and Adjust"

Test Product Link

Product Link may need up to 15 minutes in order to establish communication with a satellite. Allow a minimum of 15 minutes to complete the following procedure.

In order to establish communication, the antenna for the Product Link module must have a clear view of the sky. Objects that obstruct the antenna's view of the sky may result in a failure. If the antenna was obstructed during the test, retest the Product Link system with an unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees above the horizon. Check the following web site for satellite coverage in your area:

http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html

1. Connect Caterpillar Electronic Technician (ET) to the machine. The ET connector is located on the control panel on the right side of the cab.

2. Turn the engine start switch to the ON position.

3. Open the ET software program.

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Illustration 102	g01879234

4. ET will display a list of available electronic control modules. Select "Product Link". Press the "OK" button.

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Illustration 103	g01879236

5. Select "Diagnostic Tests" from the "Diagnostics" menu. Select "Wiggle Test".

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Illustration 104	g01879253

6. Read the warning that appears on the screen. Select the "OK" button.

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Illustration 105	g01879255

7. Select the "Groups" button near the bottom right corner of the screen.

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Illustration 106	g01879256

8. Choose the "New" button in order to create a new group for Product Link.

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Illustration 107	g01879257

9. Type "Product Link". Select the "OK" button.

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Illustration 108	g01879259
Available parameters and location of right arrow

10. In the left-hand column of available parameters, select "Number of GPS Satellites" under "Product Link". Then select the right arrow. In the left-hand column, select "Satellite Communications Status" under "Product Link". Select the right arrow.

11. Select the "OK" button.

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Illustration 109	g01879260

12. Select "Product Link". Press the "OK" button.

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Illustration 110	g01879262

13. In order to confirm the two types of communication with the satellite, the "Number of GPS Satellites" should be at least one. The "Satellite Communication Status" should be "Established". The screen in Illustration109 shows that communication with GPS and the satellite is established.

    If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Established", the communication of Product Link is confirmed.

    If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Not Established", the wiggle test can be run in order to monitor status of the communication. Select the "Start" button in order to begin the wiggle test.

    Note: Leave ET running and do not navigate to a different screen in ET while the wiggle test is running. These actions will end the wiggle test. Allow the wiggle test to run for at least 15 minutes before failing Product Link.

    If a parameter changes during the wiggle test, the parameter will be highlighted in red. A 2 second beep will sound an alert. The parameter will remain red even if the parameter changes back to the original value.

    If communication is not established and the test has run for more than 15 minutes, check the antenna for damage. Also check the connection between the antenna and the radio. If the cable does not have a good connection, reconnect the cable. Repeat the test.

    If the connection between the antenna and the radio is good and no communication is established, refer to Troubleshooting, RENR7911, "Product Link 121/321".