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994K Large Wheel Loader Field Assembly Manual Caterpillar


Bumper - Install

Usage:

994K MM9

Parts and Specification Information

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Illustration 1g06006032
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Illustration 2g06006123
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Illustration 3g06006665

Note: Verifying all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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Table 1
389-4808 Rear Bumper Ar 
Item  Part Number  Part Description  Qty  Specification  Approximate Weight 
1  389-4808  Rear Bumper Ar  1    7489 kg (16510 lb) 
2  275-3530  Strip(1)  4     
3  8T-4195  Bolt(1)  2     
4  8T-4121  Hard Washer(1)  2     
5  275-3531  Strip(1)  4     
6  6M-1622  Dowel(1)  2     
7  7X-2581  Bolt(1)  24     
8  198-4783  Hard Washer(1)  24     
9  329-3356  Nut(1)  3     
10  8X-1401  Pin(1)  1     
11  8X-1400  Rod As(1)  1     
12  415-6489  Handrail As(2)  1     
13  9X-2040  Screw(3)  8     
14  415-6411  Guardrail As(2)  1     
15  415-6495  Handrail As(2)  1     
16  8T-4183  Bolt(3)  20     
17  7X-3392  Hard Washer(3)  18     
18  415-6431  Guard(4)  1     
19  8T-4136  Bolt(3)  4     
20  5C-7261  Nut(5)  8     
21  8T-4224  Hard Washer(5)  8     
22  8T-4192  Bolt(5)  18     
23  5P-1076  Hard Washer(5)  20     
24  415-6429  Guard(4)  1     
25  248-0102  U-Bolt(5)  4     
26  415-6493  Handrail As(2)  1     
27  415-6410  Guardrail As(2)  2     
28  8T-4223  Hard Washer(3)  2     
29  5P-7468  Clip(3)  2     
30  352-8156  Guardrail As(2)  1     
31  6V-1874  Grommet(3)  2     
32  5P-7469  Clip(3)  2     
33  115-3580  Plate(3)  1     
34  415-6430  Guard(4)  1     
35  470-3494  Guard Plate(4)  1     
36  432-4296  Cable As  1     
37  467-7234  Hose As  1     
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(1) Part of the 420-8169 Bumper Mounting Gp
(2) Part of the 389-4618 Handrail Gp
(3) Part of the 415-6485 Handrail Fastener Gp
(4) Part of the 389-4608 Protection Guard Gp
(5) Part of the 415-6486 Handrail Fastener Gp

Installation Procedure

Bumper - Install

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Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
A(1)  9U-7536  Lift Stand  4 
A1  OR 
504-9826 Lift Gp (50/60 Hz)(2)  4 
504-9827 Lift Gp (50/60 Hz)(3)  4 
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(1) Use Tooling (A) or (A1) based on requirements.
(2) Operating-voltage (380-500V)
(3) Operating-voltage (180-300V)

Note: All mounting and contact surfaces must be cleaned prior to installation.

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    Illustration 4g06008595
    (6) 6M-1622 Dowel

  1. Install two dowels (6) into the location that is shown on the bottom side of the frame rails. Dowels (6) will aid in the installation of the bumper arrangement.
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    Illustration 5g06167804
    For Tooling (A)

  2. Install Tooling (A).
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    Illustration 6g06370913
    For Tooling (A1)

  3. Install Tooling (A1). Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (A1).
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    Illustration 7g06014200
    (1) 389-4808 Rear Bumper Ar
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    Illustration 8g06370914
    (7) 7X-2581 Bolt
    (8) 198-4783 Hard Washer

  4. Use a suitable lift truck to install rear bumper arrangement (1). The weight of bumper arrangement is approximately 7489 kg (16510 lb). Align the mounting holes in the bumper with the mounting holes in the frame.

  5. Install 24 bolts (7), and 24 hard washers (8).

    Note: Do not remove the support of the lift truck or the lifting device until all the mounting bolts have been tightened.

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    Illustration 9g06008811
    (1) 389-4808 Rear Bumper Ar
    (2) 275-3530 Strip
    (3) 8T-4195 Bolt
    (4) 8T-4121 Hard Washer
    (5) 275-3531 Strip

  6. Install strips (2) and strips (5) as needed. Secure strips (2) and strips (5) using bolts (3) and hard washers (4).
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    Illustration 10g06012414
    (1) 389-4808 Rear Bumper Ar
    (9) 329-3356 Nut
    (10) 8X-1401 Pin
    (11) 8X-1400 Rod As

  7. Install nut (9) onto rod assembly (11) until fully seated. Install pin (10) onto rod assembly (11) until fully seated onto nut (9). Tighten nut (9) onto pin (10).

Bumper Lines and Wiring - Connect

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    Illustration 11g06011837
    (36) 432-4296 Cable As

  1. Connect cable assembly (36) to the enclosure assembly in the location that is shown.

    Note: Cable assembly (36) was installed onto the bumper prior to the bumper installation.

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    Illustration 12g06011842
    (37) 467-7234 Hose As

  2. Connect hose assembly (37) to the fan bypass control valve group.

    Note: Hose assembly (37) was installed onto the bumper prior to the bumper installation.

Handrail Group - Install

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    Illustration 13g06012965
    (4) 8T-4121 Hard Washer
    (12) 415-6489 Handrail As
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer
    (19) 8T-4136 Bolt

  1. Install handrail assembly (12), two bolts (19), two hard washers (4), two bolts (16), and two hard washers (17).
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    Illustration 14g06012796
    (13) 9X-2040 Screw
    (14) 415-6411 Guardrail As
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer

  2. Install guardrail assembly (14), two bolts (16), two hard washers (17), and four screws (13).
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    Illustration 15g06012798
    (15) 415-6495 Handrail As
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer

  3. Install handrail assembly (15), two bolts (16), and two hard washers (17).
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    Illustration 16g06012800
    (20) 5C-7261 Nut
    (21) 8T-4224 Hard Washer
    (22) 8T-4192 Bolt
    (23) 5P-1076 Hard Washer
    (24) 415-6429 Guard
    (25) 248-0102 U-Bolt

  4. Install guard (24), four bolts (22), four hard washers (23), two U-bolts (25), two nuts (20), and two hard washers (21).
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    Illustration 17g06012808
    (18) 415-6431 Guard
    (22) 8T-4192 Bolt
    (23) 5P-1076 Hard Washer

  5. Install guard (18), four bolts (22), and four hard washers (23).
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    Illustration 18g06012416
    (4) 8T-4121 Hard Washer
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer
    (19) 8T-4136 Bolt
    (26) 415-6493 Handrail As

  6. Install handrail assembly (26), two bolts (4), two hard washers (19), two bolts (16), and two hard washers (17).
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    Illustration 19g06012418
    (13) 9X-2040 Screw
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer
    (27) 415-6410 Guardrail As

  7. Install guardrail assembly (27), four bolts (16), four hard washers (17), and four screws (13).
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    Illustration 20g06012420
    (9) 329-3356 Nut
    (16) 8T-4183 Bolt
    (17) 7X-3392 Hard Washer
    (23) 5P-1076 Hard Washer
    (28) 8T-4223 Hard Washer
    (29) 5P-7468 Clip
    (30) 352-8156 Guardrail As
    (31) 6V-1874 Grommet
    (32) 5P-7469 Clip
    (33) 115-3580 Plate

  8. Install guardrail assembly (30), four bolts (16), and four hard washers (17).

  9. Secure guardrail assembly (30) using two grommets (31), two clips (29), two clips (32), plate (33), two bolts (16), two hard washers (23), two hard washers (28), and two nuts (9).

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