854G Wheel Dozer Machine Systems Caterpillar

Front Frame and Rear Frame - Separate

Usage:

854G 1JW

Separation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	6V-3175	Hydraulic Puller Assembly	1
	9U-5346	Nut	1
	9U-5344	Puller Stud	1
	6V-4035	Sleeve	1
	350-7768	Electric Hydraulic Pump	1
B	504-9826	Lift Gp (50/60 Hz)⁽¹⁾	4
	OR
	504-9827	Lift Gp (50/60 Hz)⁽²⁾	4
D	8S-7640	Stand	2
D	8S-7621	Tube	2
E	350-7768	Electric Hydraulic Pump	1
	9U-6814	Puller Stud	1
	124-4640	Sleeve	1
	5P-5212	Plate	1
	465-6061	Cylinder Group	1
	9U-6810	Nut	1
F	350-7768	Electric Hydraulic Pump	1
	9U-6814	Puller Stud	1
	5P-5212	Plate	1
	465-6061	Cylinder Group	1
	9U-6810	Nut	1
	124-4641	Sleeve	1
	124-4638	Plate	1
G	350-7768	Electric Hydraulic Pump	1
	9U-6814	Puller Stud	1
	5P-5212	Plate	1
	465-6061	Cylinder Group	1
	9U-6810	Nut	1
	124-4641	Sleeve	1
	124-4639	Plate	1

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⁽¹⁾	High-Voltage (380-500V)
⁽²⁾	Low-Voltage (180-300V)

Start By:

Remove the cab and the platform.
Remove the center drive shaft.

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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, PERJ1017, "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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At operating temperature the implement hydraulic oil tank is hot and under pressure. Hot oil can cause burns.

To prevent possible injury, release the pressure in the implement hydraulic system before hydraulic lines or components are disconnected or removed.

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At operating temperature, the steering and brake hydraulic oil tank is hot and under pressure. Hot oil can cause burns.

To prevent possible personal injury, release the pressure in the steering and brake hydraulic system before hydraulic lines or components are disconnected or removed.

Note: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses, and all tubes. This will help to prevent fluid loss and this will help to keep contaminants from entering the system.

Drain the oil from the implement hydraulic tank into a suitable container. The capacity of the implement hydraulic tank is 326 L (85 US gal).
Drain the oil from the hydraulic tank for the steering system and for the braking system into a suitable container. The capacity of the hydraulic oil tank for the steering and brakes is 159 L (41 US gal).
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Illustration 1 g00403759

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Illustration 2 g00403838
Disconnect hydraulic hose assemblies (3) from the rear frame assembly.
Remove clamp (2) that secures harness (1) to the rear frame assembly.
Disconnect harness connector (5), and remove clip (4).
Tie the disconnected hose assemblies and the disconnected electric harness to the front frame assembly.
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Illustration 3 g00326207

Note: Because the steering cylinder pin is a slip fit in the bores, the pin can be easily removed without the use of special tooling. If removal of the steering cylinder pin requires excessive force, perform Steps 7 and 8.
Remove pin retainer (6) and steering cylinder pin (7).
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Illustration 4 g00326208
Assemble Tooling (A) on the head end of the steering cylinder pin. Use Tooling (A) to remove the steering cylinder pin.
Repeat Step 7 to remove the steering cylinder pin on the opposite side of the machine.
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Illustration 5 g06357831

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Illustration 6 g06357862

Typical example
Position Tooling (B) under the front part of the rear frame assembly on each side and under the rear bumper. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (B).
Note: Tooling (B) is positioned under the frame rails of the rear frame assembly. Make sure that the machine is resting on Tooling (B) so that the rear frame assembly is properly stabilized.
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Illustration 7 g00403899
Install Tooling (D) or suitable stands under the front frame assembly, as shown. Adjust the height of Tooling (D) so that the tooling may be easily moved as the front frame assembly is moved away from the rear frame assembly.
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Illustration 8 g00403900
Attach a hoist and suitable lifting chains to the front frame assembly, as shown. The approximate weight is 12260 kg (27000 lb).
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Illustration 9 g00403901
Place the forks of a suitable lift truck under the front frame assembly, as shown. Use suitable chains to secure the lift truck to the front frame assembly.
Note: Steps 16 through 30 are for the removal of the upper hitch pin and the lower hitch pin.
Note: If excessive force is required to pull the upper hitch pin and the lower hitch pin, refer to Steps 14 and 15.
Support the front frame assembly and the rear frame assembly. Do not allow the frame assemblies to bind. Excessive force will be required to remove the hitch pins.
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Illustration 10 g00403981
Install two pieces of channel iron to the upper hitch and lower hitch that are on the rear frame assembly, as shown. The size of the channel iron is 3.0 m (9.84 ft) long, 76 mm (3.0 inch) wide, and 9.4 mm (0.37 inch) thick. Place a uniform weld on each side of the channel iron at each hitch mounting plate. This will support the hitch mounting plates as the hitch pin is removed.
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Illustration 11 g00403965
Remove bolts (8), bolts (9), and plate (10) from the bottom of the lower hitch.
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Illustration 12 g00403966
Remove hexagonal cap (11) from lower hitch pin (12).
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Illustration 13 g00404099
Install Tooling (E) on the lower hitch pin.
Use Tooling (E) to remove lower hitch pin.
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Illustration 14 g00403905
Remove bolts (14), plate (13), and the shims (hidden) from the bottom of the upper hitch.
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Illustration 15 g00403907
Remove hose assemblies (15), (16), and (17).
Remove two neutralizer valves and mounting group (18).
Remove bracket assembly (19).
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Illustration 16 g00403909

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Illustration 17 g00403959
Remove bolts (21) and (20).
Remove plate (22) from the top of the upper hitch.
Remove shims (23).
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Illustration 18 g00403961

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Illustration 19 g00403963
Install Tooling (E) on the upper hitch pin.
Place shims in the area, as shown. Refer to Illustration 19. This will prevent the front frame assembly from lifting as the upper hitch pin is removed.
Use Tooling (E) to remove the upper hitch pin.
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Illustration 20 g00404084
Use the hoist to remove Tooling (E) and the upper hitch pin. The combined weight of Tooling (E) and of the upper hitch pin is 159 kg (350 lb). The weight of the upper hitch pin is 70 kg (155 lb).
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Illustration 21 g00404359
Separate steering frame lock (24).
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Illustration 22 g00326223
Make sure that spacer (25) at the bottom of the upper hitch does not hang up on the rear frame assembly during separation.
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Illustration 23 g00403968

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Illustration 24 g00403969
Slowly pull the front frame assembly away from the rear frame assembly. Continue to move the stands, the hoist, and the lifting chains. Refer to Step 11. Pull the front frame assembly until the two assemblies are separated by approximately 610 mm (24 inch).
Chock the front tires and lower the front frame assembly onto Tooling (D). The bearings and the seals can be serviced now.
Note: Steps 35 through 41 are for the removal of the upper hitch bearings.
Remove spacer (25) from the upper hitch assembly.
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Illustration 25 g00326226
Disconnect grease tube (26) from the lower cap of the upper hitch.
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Illustration 26 g00326227

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Illustration 27 g00326228
Mark the radial positions of upper cap (28) and of lower cap (29).
Remove bolts (27), lower cap (29), and upper cap (28).
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Illustration 28 g00326229
Remove shims (30).
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Illustration 29 g00326230
Install Tooling (F) to the upper hitch assembly. Use Tooling (F) to remove the two bearing cups and the two bearing cones from the bore in the upper hitch.
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Illustration 30 g00326231
Remove lip seal (31) from the upper cap and from the lower cap of the upper hitch assembly.
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Illustration 31 g00326232

Note: Steps 42 through 45 are for the removal of the lower hitch bearings.
Remove bolts (32) and cap (33) from the hitch assembly of the front frame assembly.
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Illustration 32 g00326234
Remove shims (34).
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Illustration 33 g00326233
Remove bolts (35) and lower cap (36) from the lower hitch.
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Illustration 34 g00326235
Install Tooling (G) to the lower hitch assembly. Use Tooling (G) to remove the two bearing cups and the two bearing cones from the bore in the lower hitch.
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Illustration 35 g00326236
Remove lip seal (37) from the upper cap and from the lower cap of the lower hitch assembly.