854K Wheel Dozer and 992K Wheel Loader Machine Systems Caterpillar

Connection Procedure

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When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

Note: Check the bearings, the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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

   Note: Steps 2 through 13 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	g01513248

   Note: Make sure that the sealing lip of lip seal (45) in the upper cap is facing toward the outside of the cap. Make sure that the sealing lip of lip seal (45) in the lower cap is facing toward the inside the cap.

2. Use Tooling (H) to install lip seals (45) in the caps of the lower hitch assembly.

3. Apply Tooling (J) to the sealing lip of each lip seal (45).

4. Apply Tooling (K) to the bores of the lower hitch.
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   Illustration 3	g01513236

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   Illustration 4	g01513352
   Lower Hitch Assembly

5. Install lower cap (40). Install bolts (39). Tighten bolts (39) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

6. Lower the temperature of bearing cup (43). The correct temperature is −62° ± 10°C (−80° ± 50°F).

7. Install bearing cup (43) in the bore of the lower hitch. Use a suitable driver to ensure that bearing cup (43) contacts lower cap (40).

8. Apply clean oil to bearing cone (44) and bearing cone (42). Install bearing cone (44) and bearing cone (42).

9. Lower the temperature of bearing cup (41). The correct temperature is −62° ± 10°C (−80° ± 50°F).

10. Install bearing cup (41) in the bore of the lower hitch. Make sure that bearing cup (41) lightly contacts bearing cone (42).
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    Illustration 5	g01513233

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    Illustration 6	g01513432

11. Install 1.58 mm (0.062 inch) of shims (38) under cap (37). Secure cap (37) with three bolts (36) that are spaced at 120 degree intervals.
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    Illustration 7	g01513436

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

12. Attach Tooling (L) to the bearing cones of the lower hitch. Use a torque wrench and Tooling (L) 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	g01513231

13. When the correct rolling torque is achieved, remove Tooling (L) and install remaining bolts (36) onto cap (37).

    Note: Steps 14 through 29 are for the assembly of the upper hitch bearings of the front frame assembly.

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    Illustration 9	g01513445

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    Illustration 10	g01513224

    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 the cap.

14. Use Tooling (H) to install lip seals (35) in the caps of the upper hitch assembly.

15. Apply a light coat of Tooling (J) to the sealing lip of each seal.

16. Apply Tooling (K) to all bores of the upper hitch.
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    Illustration 11	g00326237

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    Illustration 12	g01513457
    Upper Hitch Assembly

17. Install lower cap (29). Install three bolts (27) that are equally spaced from each other.

18. Lower the temperature of bearing cup (33). The correct temperature is −62° ± 10°C (−80° ± 50°F).

19. Install bearing cup (33) in the bore of the upper hitch. Use a suitable driver to ensure that bearing cup (33) contacts lower cap (29).

20. Lubricate bearing cone (32) and bearing cone (34) with clean oil. Install bearing cone (32) and bearing cone (34).

21. Lower the temperature of bearing cup (31). The correct temperature is −62° ± 10°C (−80° ± 50°F).

22. Install bearing cup (31) in the bore of the upper hitch. Make sure that bearing cup (31) lightly contacts bearing cone (32).
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    Illustration 13	g00326229

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    Illustration 14	g00326238

23. Install 1.85 mm (0.073 inch) of shims (30) under upper cap (28). Secure the upper cap with three bolts (27) that is spaced at 120 degree intervals.
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    Illustration 15	g01513840

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

24. Attach Tooling (M) to the bearing cones of the upper hitch. Use a torque wrench and Tooling (M) to check the rolling torque. The rolling torque must be between 14.7 N·m (11 lb ft) and 32.8 N·m (24 lb ft). 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.

25. When the correct rolling torque is achieved, remove Tooling (M) and install bolts (27). Tighten bolts (27) to a torque of 150 ± 20 N·m (110 ± 15 lb ft). Tighten bolts (27) for an extra 120° ± 10°.
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    Illustration 17	g00326226

26. Connect tube assembly (26) to 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 18	g02595859

27. Attach suitable chains to the front frame assembly. The suitable chains must be capable of supporting approximately 12260 kg (27000 lb). Use the suitable chains to raise the rear portion of the front frame assembly enough to pass over the stands.
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    Illustration 19	g00326223

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    Illustration 20	g00385694

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

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

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    Illustration 21	g00403968

29. Use a suitable lift truck to slowly push the front frame assembly toward the rear frame assembly. Move the suitable lifting device and Tooling (D) with the front frame assembly until the front hitch and the rear hitch are in alignment.
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    Illustration 22	g06400766
    Typical Example For Tooling (B)

30. Use Tooling (B) to precisely align the upper hitch and the lower hitch.

    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 23	g06400761
    Typical Example For Tooling (B1)

31. Use Tooling (B1) to precisely align the upper hitch and the lower hitch. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (B1).

    Note: Tooling (B1) can be operated independently to help in aligning the upper pin bore and the lower pin bore.

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    Illustration 24	g01513619

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

33. Install Tooling (N) in the plate assembly for handling.

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

35. Install Tooling (P) in the threaded holes in the upper hitch of the rear frame assembly.

36. Use a suitable lifting device to install the upper hitch pin in the bores of the frame. Use Tooling (P) to align the outer hole pattern of plate (22) and the hole pattern of the upper frame.

    Note: Allow all components to reach a uniform temperature before you adjust the shims.

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    Illustration 25	g01513634

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

38. Use a suitable lifting device and Tooling (R) to install lower hitch pin (12) into the bores of the lower hitch.
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    Illustration 26	g00403965

39. Install lower plate (10). Install bolts (9) and bolts (8).
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    Illustration 27	g00403966

40. Install hexagonal cap (11) in the threaded hole of lower hitch pin (12).

41. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
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    Illustration 28	g01513636

    Note: Steps 42 through 46 will determine the shim pack thickness for the upper hitch.

42. Install plate (13) and bolts (14).

43. Position Tooling (S) 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 29	g00403905

44. Remove plate (13) and add the measured number of shims from Step 43. Tighten bolts (14) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
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    Illustration 30	g01513813

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

    1. Tighten bolts (21).

       Note: Do not tighten bolts (20) now.

    2. Position Tooling (S) 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 31	g00403959

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    Illustration 32	g00403909

46. Remove plate (22) and add the number of shims (23) from Step 45. Install bolts (20). Install bolts (21). Tighten bolts (21) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
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    Illustration 33	g02699780

47. Install bracket assembly (19).

48. Install neutralizer valves and mounting bracket (18).

49. Connect hose assemblies (15), hose assemblies (16), and hose assemblies (17).
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    Illustration 34	g00326207

50. Install pin assembly (7) and pin retainer (6). Repeat this step for the steering cylinder on the opposite side of the machine.
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    Illustration 35	g02477146

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    Illustration 36	g01461267

51. Connect harness assemblies (1). Tighten the screw for harness assemblies (1) to a torque of 6.0 + 1.5 - 1.0 N·m (53.10 + 13.28 - 8.85 lb in). Install harness clip (5).

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

53. Connect hose assemblies (3) and (4).

54. Lubricate the upper hitch assembly and the lower hitch assembly. Refer to the Operation and Maintenance Manual, "Articulation Bearings - Lubricate" for the correct procedure.

55. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.

56. 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.

3. Install the push arms and the blade.