854G Wheel Dozer Machine Systems Caterpillar

Connection Procedure

Note: Replace all bearings, all seals, and all shim packs with new parts. Replace all 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 12 are for the assembly of the lower hitch bearings of the front frame assembly.

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   Illustration 1	g00326251

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   Illustration 2	g00326236

   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 inside the cap.

2. Use Tooling (A) and install lip seals (37) in the caps of the lower hitch assembly.

3. Lubricate the sealing lip of each seal lightly with 5P-0960 Molybdenum Grease.

4. Apply 5P-3931 Anti-Seize Compound to the bores of the lower hitch.

5. Lower the temperature of the bearing cups. The correct temperature is −62° ± 10°C (−80° ± 50°F).
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   Illustration 3	g00326249

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   Illustration 4	g00326248
   Lower Hitch Assembly

6. Install lower cap (36). Install three bolts (35) that are equally spaced from each other. The torque for bolts (35) is 100 ± 20 N·m (75 ± 15 lb ft).

7. Use insulated gloves to install lower bearing cup (39) in the bore of the lower hitch. Use a suitable driver to ensure that bearing cup (39) contacts lower cap (36).

8. Apply clean oil to bearing cones (40) and (41). Install bearing cones (40) and (41), as shown.

9. Use insulated gloves to install upper bearing cup (38) in the bearing housing. Make sure that the bearing cup contacts the bearing cones lightly.
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   Illustration 5	g00326234

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   Illustration 6	g00326247

   Note: Use new bolts (32) for the final assembly of the lower hitch bearings.

10. Install 1.58 mm (.062 inch) of shim pack (34) under upper cap (33). Secure the upper cap with three bolts (32) that is spaced at 120 degree intervals. The torque for bolts (32) is 100 ± 20 N·m (75 ± 15 lb ft).
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    Illustration 7	g00326246

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

11. Attach Tooling (E) to the bearing cones of the lower hitch. Use a torque wrench and Tooling (E) to check the rolling torque. The rolling torque must be between 2.26 N·m (20 lb in) and 7.91 N·m (70 lb in). Add shims or remove shims, as required.
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    Illustration 8	g00326232

    Note: Use new bolts (32) for the final assembly of the lower hitch bearings.

12. When the correct rolling torque is achieved, remove Tooling (E) and install remaining three bolts (32). Tighten all six bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

    Note: Steps 13 through 25 are for the assembly of the upper hitch bearings of the front loader frame.

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    Illustration 9	g00326245

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    Illustration 10	g00326231

    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 inside the cap.

13. Use Tooling (A) to install lip seals (31) in the caps of the upper hitch assembly.

14. Lubricate the sealing lip of each seal lightly with 5P-0960 Molybdenum Grease.

15. Apply 5P-3931 Anti-Seize Compound to all bores of the upper hitch.

16. Lower the temperature of the bearing cups. The correct temperature is −62° ± 10°C (−80° ± 50°F).
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    Illustration 11	g00326237

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    Illustration 12	g00326253
    Upper Hitch Assembly

    Note: Use new bolts (27) for the final assembly of the upper hitch bearings.

17. Install lower cap (29). Install three bolts (27) that are equally spaced from each other. The torque for bolts (27) is 240 ± 40 N·m (175 ± 30 lb ft).

18. Use insulated gloves to install lower bearing cup (43) in the bore of the lower hitch. Use a suitable driver to ensure that bearing cup (43) contacts lower cap (29).

19. Lubricate the bearing cones with clean oil. Install bearing cones (44) and (45), as shown.

20. Use insulated gloves to install upper bearing cup (42) in the bearing housing. Make sure that the bearing cup contacts the bearing cones lightly.
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    Illustration 13	g00326229

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    Illustration 14	g00326238

21. Install 0.85 mm (.034 inch) of shim pack (30) under upper cap (28). Secure the upper cap with three bolts (27) that is spaced at 120 degree intervals. The torque for the bolts is 240 ± 40 N·m (175 ± 30 lb ft).
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    Illustration 15	g00326239

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

22. Attach Tooling (F) to the bearing cones of the upper hitch. Use a torque wrench and Tooling (F) to check the rolling torque. The rolling torque must be between 14.7 N·m (130 lb in) and 32.8 N·m (290 lb in). Add shims or remove shims, as required.
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    Illustration 16	g00326227

    Note: Use new bolts (27) for the final assembly of the upper hitch bearings.

23. When the correct rolling torque is achieved, remove Tooling (F) and install the remaining nine bolts (27). Tighten all12 bolts to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
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    Illustration 17	g00326226

24. Connect grease tube (26) to the lower cap of the upper hitch.
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    Illustration 18	g00404101

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    Illustration 19	g00385694

25. Install spacer (25) in the lower cap of the upper hitch.

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

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    Illustration 20	g00403969

26. Use a hoist and suitable lifting chains to raise the rear portion of the front frame assembly enough to pass over the stands.
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    Illustration 21	g00326223

    Note: Make sure that spacer (25) of the upper front hitch does not hang up on the upper rear hitch during the connection procedure.

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    Illustration 22	g00403968

27. Use a lift truck to push the front frame assembly toward the rear loader frame. Move the hoist and the stands with the front loader frame until the front hitch and the rear hitch are in alignment.
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    Illustration 23	g06357831

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    Illustration 24	g06357862
    Typical example

28. Use Tooling (B) to align the upper hitch and the lower hitch. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (B).

    Note: Tooling (B) can be operated independently to help in aligning the upper pin bore and the lower pin bore.

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    Illustration 25	g00404102

29. Install retainer plate (22) and bolts (21) to the upper pin.

30. Install Tooling (K) in the plate assembly for handling.

31. Lower the temperature of the pin and the plate assembly to −62° ± 10°C (−80° ± 50°F).

32. Install Tooling (H) in the threaded holes in the upper hitch of the rear frame assembly.

33. Use a hoist and suitable lifting chains to install the upper hitch pin in the bores of the frame. Use Tooling (H) to align the outer hole pattern of plate (22) and the hole pattern of the upper frame.

    Note: Allow the pin assembly to reach an ambient temperature before you adjust the shims.

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    Illustration 26	g00404231

34. Lower the temperature of lower hitch pin (12) to −62° ± 10°C (−80° ± 50°F).

35. Use a hoist and Tooling (G) to install lower hitch pin (12) into the bores of the lower hitch.
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    Illustration 27	g00403965

36. Install lower plate (10). Install bolts (9) and bolts (8). The torque for bolts (8) and (9) is 240 ± 40 N·m (175 ± 30 lb ft).
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    Illustration 28	g00403966

37. Install hexagonal cap (11) in the threaded hole of lower hitch pin (12).
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    Illustration 29	g00404359

38. Connect steering frame lock (24).
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    Illustration 30	g00404104

    Note: Steps 39 through 43 will determine the shim pack thickness for the upper hitch.

39. Install plate (13) and bolts (14). The torque for the bolts is 460 ± 60 N·m (340 ± 45 lb ft).

40. Position Tooling (J) through the small hole near the center of plate (13). Measure the distance from the bottom surface of plate (13) to the pin. Measure the thickness of plate (13) and subtract that amount from the original distance that was measured. This determines the number of shims that is needed under plate (13).
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    Illustration 31	g00403905

41. Remove plate (13) and add the measured number of shims from Step 40. Tighten six bolts (14) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
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    Illustration 32	g00404106

42. Use the following steps to determine the shim pack that is required for upper plate (22).

    1. Tighten six bolts (21) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

       Note: Do not tighten bolts (20) now.

    2. Position Tooling (J) through the small hole near the outside bolt pattern of plate (22).

    3. Measure the distance from the top of plate (22) to the surface of the upper boss.

    4. To determine the required number of shims, subtract the thickness of plate (22) from the measured distance.
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    Illustration 33	g00403959

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    Illustration 34	g00403909

43. Remove plate (22) and add the amount of shims (23) from Step 42. Tighten 12 bolts (20) to a torque of 240 ± 40 N·m (175 ± 30 lb ft). Tighten six bolts (21) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
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    Illustration 35	g00403907

44. Install bracket assembly (19).

45. Install the neutralizer valves and mounting plate (18).

46. Install hose assemblies (15), (16), and (17).
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    Illustration 36	g00326207

47. Install steering cylinder pin (7) and pin retainer (6). Repeat this step for the steering cylinder on the opposite side of the machine.
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    Illustration 37	g00403838

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    Illustration 38	g00403759

48. Connect harness connector (5). Install harness clip (4).

49. Install clamp (2) to fasten harness (1) to the rear main frame.

50. Connect nine hydraulic hose assemblies (3).

51. Lubricate the upper hitch assembly and the lower hitch assembly. Refer to the Operation and Maintenance Manual, SEBU7142 for the correct procedure.

52. Fill both hydraulic tanks with oil. Refer to the Operation and Maintenance Manual, SEBU7142 for the correct procedure.

53. Start the engine and check for leaks. Check for proper operation of the implements.

    Note: After the steering frame lock is separated, check for proper operation of the steering system and of the brakes.

End By:

1. Install the center drive shaft.

2. Install the cab and the platform.

3. Separate the steering frame lock.