836K Landfill Compactor and 834K Wheel Dozer Machine Systems Caterpillar

Connection Procedure

Note: Replace all bearings, all seals, and all shim packs with new parts. Replace all of the O-ring seals in the hose connections and in the tube connections.

1. Thoroughly clean the bores of the upper hitch and of the lower hitch.

   Note: Steps 2 through 14 are used for the assembly of the lower hitch bearings of the front frame.

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   Illustration 1	g02108797

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   Illustration 2	g03505787

   Note: Make sure that the sealing lip of the lip seal in the upper cap is facing toward the outside of the cap. Make sure that the sealing lip of the lip seal in the lower cap is facing toward the inside of the cap.

2. Use Tooling (K) in order to install lip seals (32) in the caps of the lower hitch assembly.

3. Lubricate the sealing lip of each seal lightly with Tooling (R).

4. Coat all bores of the lower hitch with Tooling (S).
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   Illustration 3	g03505818
   Typical Example

5. Use three of bolts (28) in order to secure lower cap (30) to the lower hitch.
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   Illustration 4	g03505828

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   Illustration 5	g03505835
   Lower Hitch Assembly

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   Illustration 6	g03505840

6. Lower the temperature of bearing cups (33) and (34).

7. Install bearing cup (35). Use Tooling (K) in order to make sure that bearing cup (35) contacts the lower cap.

8. Lubricate bearing cones (34) and (36) with clean oil. Install bearing cone (34) and bearing cone (36).

9. Install upper bearing cup (33) in the bearing housing. Use Tooling (K) in order to make sure that bearing cup (33) contacts the bearing cones lightly.
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   Illustration 7	g03505845

10. Install original shims (31) under the upper cap. If a new shim pack is being installed, use 1.5 mm (0.06 inch) of the new shim pack.
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    Illustration 8	g03505857
    Typical Example

    Note: Adding shims will decrease the rolling torque. Removing shims will increase the rolling torque.

11. Secure upper cap (29) with four of bolts (28) that are spaced at 90 degree intervals.

12. Attach Tooling (L) to the bearing cones of the lower hitch.

13. Use a suitable torque wrench and Tooling (L) in order to check the rolling torque. The rolling torque must be between 12 N·m (107 lb in) and 22 N·m (195 lb in). Add shims or remove shims, as required.
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    Illustration 9	g03505773

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    Illustration 10	g03505776

14. Remove Tooling (L) and install bolts (28) in order to secure upper cap (29) and lower cap (30).

    Note: Steps 15 through 26 are used for the assembly of the upper hitch bearings of the front loader frame.

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    Illustration 11	g02109040

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    Illustration 12	g03505768

    Note: Make sure that the sealing lip of the lip seal in the upper cap is facing toward the outside of the cap. Make sure that the sealing lip of the lip seal in the lower cap is facing toward the inside of the cap.

15. Use Tooling (K) in order to install lip seals (27) in the caps of the upper hitch assembly.
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    Illustration 13	g03505867

16. Use three of bolts (25) in order to secure lower cap (24) to the upper hitch.
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    Illustration 14	g03505876
    Upper Hitch Assembly

17. Lower the temperature of bearing cups (37) and (39).

18. Install bearing cup (39). Use Tooling (K) in order to make sure that bearing cup (39) contacts the lower cap.

19. Lubricate bearing cones (40) and (38) with clean oil. Install bearing cone (40) and bearing cone (38).

20. Install upper bearing cup (37) in the bearing housing. Use Tooling (K) in order to make sure that bearing cup (37) contacts the bearing cones lightly.
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    Illustration 15	g03505767

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    Illustration 16	g03505879

21. Install original shims (26) under upper cap (23). If a new shim pack is being installed, use 1.5 mm (0.06 inch) of the new shim pack.

22. Secure upper cap (23) with three of bolts (25) that are spaced at 120 degree intervals.
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    Illustration 17	g02109422

    Note: Adding shims will decrease the rolling torque. Removing shims will increase the rolling torque.

23. Attach Tooling (L) to the bearing cones of the upper hitch.

24. Use a suitable torque wrench and Tooling (L) in order to check the rolling torque. The rolling torque must be between 10 N·m (90 lb in) and 34 N·m (300 lb in). Add shims or remove shims, as required.
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    Illustration 18	g03505755

25. When the correct rolling torque is achieved, remove Tooling (L) and install the remaining bolts (25) onto upper cap (23).
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    Illustration 19	g03505740

26. Install spacer (22) in the lower cap of the upper hitch (21).

    Note: The following steps are used for connecting the front frame to the rear frame.

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    Illustration 20	g03505631

27. Attach Tooling (J) and a suitable lifting device to front frame (10). The weight of front frame (19) is approximately 9072 kg (20000 lb).
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    Illustration 21	g00700669
    Typical Example

28. Use the suitable lifting device in order to raise the rear portion of the front frame enough to pass over Tooling (B).
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    Illustration 22	g00749058

29. Place the forks of a suitable lift truck under the blade. Use suitable chains to secure the blade to the lift truck.

30. Use the suitable lift truck in order to slowly push the front frame toward the rear frame.

31. Move the suitable lifting device and Tooling (B) with the front frame until the front hitch and the rear hitch are in alignment.
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    Illustration 23	g01145353
    Typical Example

32. Use Tooling (A) and Tooling (C) in order to align the upper hitch and the lower hitch.

    Note: Tooling (A) and Tooling (C) can be operated independently in order to assist in aligning the upper pin bore and the lower pin bore.

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    Illustration 24	g03505887
    Typical Example

33. Attach plate (17) to the upper pin with two of bolts (16).

34. Install Tooling (P) (not shown) to plate (17).

35. Lower the temperature of plate (17) and the pin.

36. Install Tooling (M) in the threaded holes in the upper hitch of the rear loader frame.

37. Use a suitable lifting device in order to lower the upper hitch pin into the bores of the frame. The weight of the upper hitch pin is approximately 27 kg (60 lb).

38. Use Tooling (M) in order to align the outer hole pattern of plate (17) and the hole pattern of the upper frame.

    Note: Allow the pin assembly to warm to ambient temperature for 45 minutes before adjusting the shims.

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    Illustration 25	g03505895

39. Install plate (12) and three of bolts (14). Tighten bolts (14) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

40. Position Tooling (N) through the small hole near the center of plate (12).

41. Measure the distance from the bottom surface of plate (12) to the pin. Measure the thickness of plate (12) and subtract that amount from the original distance that was measured. This procedure determines the amount of shims (13) that is needed under plate (12).
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    Illustration 26	g03505657

42. Remove plate (12) and add the measured amount of shims (13) from Step 41.

43. Install plate (12) and bolts (14). Tighten bolts (14) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
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    Illustration 27	g03505900
    Typical Example

44. The following steps are used in order to determine the shims that are required for upper plate (17).

    1. Tighten bolts (16) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

       Note: Do not tighten bolts (15) at this time.

    2. Position Tooling (N) through the two small holes near the outside bolt pattern of plate (17).

    3. Measure the distance from the top of plate (17) to the surface of the upper boss in two places. Average the two measurements.

    4. To determine the required amount of shims, subtract the thickness of plate (17) from the average measurement in Step 44.c.
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    Illustration 28	g03505677

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    Illustration 29	g03505675

45. Remove plate (17) and add the amount of shims (18) that is equivalent to the average measured distance in Step 44.

46. Install plate (17). Install bolts (15) and (16). Tighten bolts (15) to a torque of 100 ± 20 N·m (74 ± 15 lb ft). Tighten bolts (16) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
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    Illustration 30	g03506137

47. Lower the temperature of lower hitch pin (20). Install lower hitch pin (20).

48. Install bolt (19).
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    Illustration 31	g03505598

49. Install bracket assembly (9). Position valve assemblies (8) and install on to bracket assembly (9).
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    Illustration 32	g03505555

50. Connect all hose assemblies (7) to the rear frame assembly.
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    Illustration 33	g03505551

51. Turn valve handles (6) to the ON position.
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    Illustration 34	g03505484

52. Connect hose assemblies (5).

53. Position harness assembly (3) and install grommets (4).

54. Connect harness assembly (3).
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    Illustration 35	g03505482

55. Install cover and bracket assemblies (2).
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    Illustration 36	g02106157

56. Install pin assembly (1). Repeat for the opposite side of the machine.

57. Lubricate the upper hitch assembly and the lower hitch assembly. For the correct procedure, refer to Operation and Maintenance Manual, "Articulation Bearings - Lubricate".

58. Fill the hydraulic tank. Refer to Operation and Maintenance Manual, "Capacities - Refill" for the capacity of the hydraulic tank. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

End By:

1. Install the center drive shaft.

2. Install the cab.