Usage:
1. Thoroughly clean the bores of the upper hitch and the lower hitch before assembly.
2. Install lower cap (33) on the lower hitch. Fasten the cap in position with five equally spaced bolts with five washers on each bolt, as shown.
NOTE: Bearing cup (36) faces upward.
3. Coat the bores of the lower hitch with 5P-3931 Anti-Seize Compound. Lower the temperature of lower bearing cup (36) to -75 ± 5°C (-103 ± 9°F). Install lower bearing cup (36) in the lower hitch, as shown. Use Tooling (A) to install the bearing cup until the bearing cup makes contact with the lower cap.
4. Put clean SAE 30 oil on bearing cone (37). Install bearing cone (37) in the lower hitch, as shown.
NOTE: The two bearing cones are installed facing opposite directions.
5. Put clean SAE 30 oil on bearing cone (38). Install bearing cone (38) in the lower hitch, as shown.
6. Lower the temperature of upper bearing cup (39) to -75 ± 5°C (-103 ± 9°F). Install upper bearing cup (39) in the lower hitch, as shown. Make sure that bearing cup (39) is down far enough to create a slight contact pressure on the bearing cones.
7. Install the original shims and upper cap (32). Fasten the cap in position with five equally spaced bolts, as shown. Tighten the bolts to a torque of 120 ± 7 N·m (90 ± 5 lb ft). Install Tooling (B) on the bearing cones. Use Tooling (B) and a torque wrench to check the rolling torque. The correct rolling torque is 11.3 to 39.6 N·m (8.3 to 29.1 lb ft). Add or remove shims to obtain the correct rolling torque.
NOTE: Adding shims will decrease the amount of rolling torque. Removing shims will increase the amount of rolling torque.
8. Remove Tooling (B), the upper cap and the lower cap. Record the correct amount of shims for later installation.
9. Use Tooling (A) to install lip seals (35) in the upper cap and the lower cap. Install lip seal (35) in the lower cap with the sealing lip toward the outside of the cap. Install lip seal (35) in the upper cap with the sealing lip toward the inside of the cap.
10. Lubricate lip seals (35) with 5P-0960 Molybdenum Grease.
NOTE: Align the upper cap and the lower cap with the alignment marks that were made during the original removal.
11. Install upper cap (32), lower cap (33) and the amount of shims that were determined during Step 7. Apply 155-0695 Thread Lock Compound to the threads of bolts (34) prior to assembly. Install ten bolts (34) and the washers and tighten to a torque of 120 ± 7 N·m (90 ± 5 lb ft).
12. Install spacer (31) in the upper cap of the lower hitch assembly, as shown.
13. Connect lubrication hose assembly (30) to the lower hitch assembly.
14. Apply 4C-9507 Compound to the hitch bores for bearing sleeves (28) and (29). Lower the temperature of bearing sleeves (28) and (29) to -75 ± 5°C (-103 ± 9°F). Install bearing sleeves (28) and (29) in the upper hitch of the rear frame, as shown. Make sure that the lower face of bearing sleeve (29) is even with the lower surface of the rear frame.
15. Install lower cap (23) on the upper hitch of the front loader frame. Fasten the cap in position with three equally spaced bolts and washers, as shown.
NOTE: Bearing cup (40) faces upward.
16. coat the bores of the upper hitch with 5P-3931 Anti-Seize Compound. Lower the temperature of lower bearing cup (40) to -75 ± 5°C (-103 ± 9°F). Install lower bearing cup (40) in the upper hitch, as shown. Use Tooling (A) to install the bearing cup until the bearing cup makes contact with the lower cap.
17. Put clean SAE 30 oil on bearing cone (41). Install bearing cone (41) in the upper hitch, as shown.
NOTE: The two bearing cones are installed facing opposite directions.
18. Put clean SAE 30 oil on bearing cone (42). Install bearing cone (42) in the upper hitch, as shown.
19. Lower the temperature of upper bearing cup (43) to -75 ± 5°C (-103 ± 9°F). Install upper bearing cup (43) in the upper hitch, as shown. Make sure that bearing cup (43) is down far enough to create a slight contact pressure on the bearing cones.
20. Install the original shims and upper cap (22). Fasten the cap in position with three equally spaced bolts, as shown. Tighten the bolts to a torque of 80 ± 7 N·m (60 ± 5 lb ft). Install Tooling (C) on the bearing cones. Use Tooling (C) and a torque wrench to check the rolling torque. The correct rolling torque is 2.3 to 13.6 N·m (20 to 120 lb inch). Add or remove shims to obtain the correct rolling torque.
NOTE: Adding shims will decrease the amount of rolling torque. Removing shims will increase the amount of rolling torque.
21. Remove Tooling (C), the upper cap and the lower cap. Record the correct amount of shims for later installation.
22. Use Tooling (A) to install lip seals (27) in the upper cap and the lower cap. Install lip seal (27) in the lower cap with the sealing lip toward the inside of the cap. Install lip seal (27) in the upper cap with the sealing lip toward the outside of the cap.
23. Lubricate lip seals (27) with 5P-0960 Molybdenum Grease.
NOTE: Align the upper cap and the lower cap with the alignment marks that were made during the original removal.
24. Install upper cap (22), lower cap (23) and the amount of shims that were determined during Step 20. Apply 155-0695 Thread Lock Compound to the threads of bolts (24) prior to assembly. Install six bolts (24) and the washers and tighten to a torque of 80 ± 7 N·m (60 ± 5 lb ft).
25. Connect lubrication hose assembly (25) (if equipped) to the upper hitch assembly.
26. Attach a hoist and suitable lifting chains to the front loader frame, as shown.
27. Place the forks of a suitable lift truck under the bucket, as shown.
28. Use Tooling (D), suitable lifting chains and a sling to secure the bucket to the mast of the lift truck, as shown.
29. Connect Tooling (E) to parking brake hose assembly (21) from the front loader frame, as shown. Operate the hydraulic pump from Tooling (E) to a pressure of 3445 kPa (500 psi). This will disengage the parking brake in the front axle group.
30. Use the hoist to raise the front loader frame.
31. Remove the wood blocks under the front loader frame.
32. Use the hoist and the lift truck to carefully push the front loader frame toward the rear frame. Push the front loader frame until the front hitch and the rear hitch are in alignment.
33. Install steering frame lock pin (18). Refer to Disassembly and Assembly, "Steering Frame Lock Pin - Remove and Install" for the machine that is being serviced.
34. Install two 1/2 inch - 13 NC x 200 mm (8 inch) guide bolts (44) in two opposite upper pin retaining bolt holes, as shown.
35. Coat the pin and pin bores of the upper hitch assembly with 5P-3931 Anti-Seize Compound. Install upper hitch pin (20). Use a soft-faced hammer to install the upper hitch pin.
36. Apply 155-0695 Thread Lock Compound to the threads of bolts (19) prior to assembly. Install four bolts (19) and the washers and tighten the bolts evenly to a torque of 120 ± 7 N·m (90 ± 5 lb ft).
37. Coat the bores of the lower hitch assembly with 5P-3931 Anti-Seize Compound. Install spacer (17) into the lower hitch assembly. Use Tooling (F) (not shown) to install spacer (17) even with the lower surface of the front loader frame.
38. Put plate (15) in position and install four bolts (13) and the washers, as shown.
39. Install two 5/8 inch - 11 NC x 300 mm (12 inch) guide bolts (45) in two opposite bolt holes in lower hitch pin (16), as shown.
40. Coat the pin and pin bores of the lower hitch assembly with 5P-3931 Anti-Seize Compound. Install lower hitch pin (16) into the bores of the lower hitch assembly. Align guide bolts (45) with the mounting holes in plate (15), as shown.
41. Use Tooling (F) and a suitable extension bar to press the lower hitch pin into position.
42. Remove two guide bolts (45) from the lower hitch pin.
43. Install plate (15) with four bolts (14) and the washers. Tighten bolts (14) to a torque of 70 ± 35 N·m (50 ± 25 lb ft).
44. Use a thickness feeler gauge to measure the distance between the frame and lower hitch mount plate (15). Check completely around the lower hitch mount plate. Take an average of the measurements to obtain the correct amount of shims needed.
45. Remove lower hitch mount plate (15).
46. Install plate (15) with the correct thickness of shims that were found in Step 44. Replace the old shims if they are worn or damaged.
47. Apply 155-0695 Thread Lock Compound to the threads of bolts (13) prior to assembly. Install eight bolts (13) and the washers and tighten to a torque of 120 ± 7 N·m (90 ± 5 lb ft).
48. Apply 4C-9507 Compound to the threads of bolts (14) prior to assembly. Install four bolts (14) and the washers and tighten to a torque of 270 ± 13 N·m (200 ± 10 lb ft).
49. Remove the wood blocks from under the machine.
50. Connect axle oil cooling hose assemblies (11) and (12) (if equipped) to the manifold in the front frame.
51. Connect four hose assemblies (10).
52. Connect four hose assemblies (9) to the bulkhead on the rear frame.
53. Connect the wiring harnesses to electrical connectors (7) and (8).
54. Install two harness clips (6).
55. Connect hose assembly (5) to the hydraulic tank.
56. Connect hose assembly (4) to the manifold in the rear frame.
57. Align the bores of the rod end of one of the steering cylinders and the front frame. Put 5P-0960 Molybdenum Grease in the pin bore and install pin (48) and shims (47) (as required).
58. Put 5P-3931 Anti-Seize Compound on the inside and outside diameters of all collets before assembly. Install collet assemblies (46) and (49).
59. Put 5P-3931 Anti-Seize Compound on the threads of bolt (3). Install bolt (3) and the washer.
NOTE: The collet on one side must not extend farther than the other collet when the bolt is tight.
60. Tighten bolt (3) to a torque of 870 ± 110 N·m (640 ± 80 lb ft). After the bolt is tight, hit the collet on each side with a heavy hammer until the torque on the bolt is less than 360 N·m (265 lb ft).
61. Tighten bolt (3) again to torque of 870 ± 110 N·m (640 ± 80 lb ft). Hit each collet again until the torque for the bolt is less than 570 N·m (420 lb ft).
62. Tighten bolt (3) to a final torque of 870 ± 110 N·m (640 ± 80 lb ft).
63. Install nut (2) and tighten to torque of 500 ± 65 N·m (370 ± 48 lb ft).
NOTE: At the end of 50 service hours after any pin and collet was installed, loosen nut (2) and tighten the bolt in each collet assembly to a torque of 870 ± 110 N·m (640 ± 80 lb ft). Retighten nut (2) to a torque of 500 ± 65 N·m (370 ± 48 lb ft).
64. Connect lubrication hose assembly (1) (if equipped) to the rod end of the steering cylinder.
65. Repeat Steps 57 through 64 for the rod end of the steering cylinder on the other side of the machine.
66. Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual for the machine that is being serviced.
End By:
a. Install the center drive shaft. Refer to Disassembly and Assembly, Power Train, "Drive Shaft (Center) - Remove and Install" for the machine that is being serviced.
b. Purge the air from the braking system. Refer to Systems Operation, Testing and Adjusting, Braking System, "Brake System Air - Purge" for the machine that is being serviced.
c. Remove the steering frame lock pin. Refer to Disassembly and Assembly, "Steering Frame Lock Pin - Remove and Install" for the machine that is being serviced.