994K Large Wheel Loader Field Assembly Manual Caterpillar

Required Parts

Illustration 1	g06020828
Cutaway View of Rod End Pin for the Lift Cylinder

Illustration 2	g06020870

Special Tools

Service Procedure

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Illustration 3	g06020394
(D) Lift arms

1. Attach cables or chains to lift arms (D).

2. Use a suitable lifting device to raise lift arms (D). Raise the lift arms until the lift cylinder pin bore is clear of the frame.
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   Illustration 4	g06020459

3. Make sure that the pin, the collars, and the installed bearings are clean, dry, and free of rust.

   Lubricate the inside diameter of each bearing, each collar, and the outside diameter of the pin. Use clean 80W90 EP gear oil. The gear oil will make assembly easier and will prevent dry spots between the pin and the bearings.

   Note: For more information on assembling the pin joint, refer to Disassembly and Assembly Manual , UENR3333.

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   Illustration 5	g06020413
   (5) Lip seal

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   Illustration 6	g06020461
   Rod eye end of lift cylinder on right-hand side of loader frame (5) Lip seal

4. Apply 7M-7456 Sealant (A) to the outside diameter of 420-1507 Pin Seal (5) before installation.

   Install two 7X-4786 Lip Seals (5) into the pin bores on the rod eye end of the lift cylinder. Verify that 7X-4786 Lip Seal (5) is seated evenly into the bore of the rod eye end on the lift cylinder.

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   Illustration 7	g06020528
   Lift Cylinder on Right-Hand Side of Loader Frame

5. Extend the lift cylinder until the rod eye end is aligned with the pin bore on the lift arm.

   Note: The grease port on the rod end of the lift cylinder should be oriented toward the front of the machine.

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   Illustration 8	g06020750
   Lifting Device for Pin (4) Pin

6. Use a lifting device to position the 389-4897 Pin (4). The weight of the pin is 144 kg (318 lb).

   Install the 8X-0662 Pin (4) into the pin bore of lift arm and the rod eye end of lift cylinder.

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   Illustration 9	g06020607
   Typical View of Linkage Pin in Pin Bore. Measurements (A) and (B) must be equal.

7. Measure the distance between the end of the pin and the lift arm. Measure both ends.

   Position the pin in the pin bore so that there is an equal space at each end of the pin.

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   Illustration 10	g06020845
   Outer Collet and Inner Collet for Rod Eye End on Lift Cylinder (1) Outside collet (2) Inside collet

   Note: The inside collet has a larger hole in the middle for the mounting bolt. The outside collet has a smaller threaded hole for the mounting bolt.

8. Apply 4C-5599 Anti-Seize Compound (C) to the inside diameter of the collets.
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   Illustration 11	g06020986
   (1) 389-4937 Collet (4) 389-4897 Pin (7) 9G-7516 Plug

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   Illustration 12	g06020988
   (2) 389-4917 Collet (3) 9X-8399 Washer (4) 389-4897 Pin (6) 3E-8010 Bolt (7) 9G-7516 Plug

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   Illustration 13	g06020990

9. Apply 4C-5599 Anti-Seize Compound (C) to the outside surface of the 389-4937 Collet (1).

   Install the collet into the pin bore on the outside of the lift arm.

   Install three Plugs (7) into the Collet (1). Torque the plugs to 12 ± 3 N·m (9 ± 2 ft lb).

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   Illustration 14	g06020992

10. Perform the following steps to complete the collet installation process.

    1. Apply 4C-5599 Anti-Seize Compound (C) to the outside surface of the 389-4917 Collet (2).

    2. Install the 389-4917 Collet (2) into the pin bore inside the lift arm.

       Note: The collets on each end of the pin should extend the same distance from the lift arm.

    3. Apply 4C-5599 Anti-Seize Compound (C) to the plugs.

    4. Install three Plugs (7) into the Collet (1). Torque the plugs to 12 ± 3 N·m (9 ± 2 ft lb).

    5. Apply 4C-5599 Anti-Seize Compound (C) to the bolt threads.

    6. Install 3E-8010 Bolt (6) with 9X-8399 Washer (3). The bolt threads should engage the threads inside the 389-4937 Collet (1).

       Note: Start the bolt from the inside collet on the lift arm.

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    Illustration 15	g06021137

11. Perform the following steps to complete the pin installation process.

    1. Tighten 3E-8010 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    2. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to 950 N·m (700 lb ft).

    3. Tighten 3E-8009 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

    4. Strike the collets and the lift cylinder rod end with a hammer until the bolt torque drops to 1600 N·m (1180 lb ft).

    5. Tighten 3E-8009 Bolt (6) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

       Note: After the bolt is tightened, each collet should extend the same distance from the lift arm.Torque the bolts after the machine has operated for 8 hours and after the machine has operated for 50 hours.

12. Repeat Steps 3 through 11 for the lift cylinder on the other side of the machine.

13. Pin joints that are equipped with lip seals will be manually filled with grease. Carefully fill the pin joint with the recommended lubricant.

    Continue to fill the pin joint until the grease is forced out of the pin and each seal.

    Note: Do not rely on the automatic lubrication system (if equipped) to fill the new pin joint.

14. Lower the lift arms to the ground.