Usage:
Front Bolster Group Installation
(1) Plate retainer. (2) Seal. (3) Shims. (4) Bearing cone. (5) Bearing cup. (6) Bearing cup. (7) Bearing cone. (8) Seal. (9) Grease hose. (10) King pin. (11) King pin housing. (12) Primary bolster.
Remove Front Bolster Group
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Empty all ballast from the machine before starting the following procedure. |
1. Park the machine on a hard, level surface. Shut the engine off and apply the parking brake.
NOTE: Remove the hood assembly, engine radiator and oil cooler, if necessary, for better access to king pin housing (11).
2. Block the front and rear wheels on both sides to ensure that the machine will not roll.
3. Disconnect the rod end of the steer cylinder from the front bolster group.
4. Disconnect water hose (13) from the inlet port of the front spray bar. Plug the hose and the inlet port to prevent contaminants from entering.
5. Disconnect grease hose (9) from plate retainer (1) on top of the king pin housing.
6. Remove three bolts and washers securing plate retainer (1) to king pin (10).
7. Remove plate retainer (1) and shims (3) from king pin housing.
8. Support the front bolster group to prevent it from rolling or falling when separated from the machine frame.
9. Lift the frame of the machine approximately 254 mm (10 in.) to separate the frame from the front bolster group. Weight of an empty machine at the front bolster group is approximately 2025 kg (4500 lbs.).
10. Move the front bolter group away from the machine frame. Lay the front bolster group down on a flat work surface. Weight of the front bolster group is approximately 432 kg (951 lbs.).
11. Set the frame of the machine down on two blocks, as shown. The height of the blocks should be approximately 267 mm (10.5 in.). Blocks must be under the sides of the frame. Do not block under the center of the machine.
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Make sure the frame is securely blocked before working on or around the machine. |
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12. Remove seals (2) and (8) from king pin housing (11) and discard. These must be replaced with new parts during assembly.
13. Lift bearing cone (4) out of the king pin housing.
14. Use a suitable puller or driver to remove bearing cups (5) and (6) from inside the king pin housing.
15. Use a suitable puller to remove bearing cone (7) from king pin (10).
16. Clean king pin (10) and the inside of the king pin housing thoroughly. Inspect these components for damage, especially in the bearing seat areas. Make sure grooves for seals (2) and (8) are free of burrs or scratches. Repair or replace any damaged components.
17. Wash bearing cups (5) and (6) and bearing cones (4) and (7) in solvent. Dry the bearings immediately after cleaning. Do not dry bearings by spinning with compressed air.
18. Inspect bearings carefully for excessive wear or damage. If necessary, replace bearing cups and cones in sets only.
19. Hand pack bearing cones (4) and (7) with no. 2 grease before installing.
Install Front Bolster Group
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Make sure the frame is securely blocked before working on or around the machine. |
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1. Press bearing cup (6) into the bottom of the king pin housing. Use a piece of wood and a hammer to tap the bearing cup in, if necessary. Tap the bearing cup all the way around to make sure it is seated squarely.
2. Press bearing cup (5) into the top of the king pin housing. Follow the same procedure as step 1 to seat the bearing cup.
3. Install a new seal (8) into the groove at the bottom of the king pin housing. Use a little no. 2 grease in the groove to prevent the seal from falling out.
4. Install a new seal (2) into the groove at the top of the king pin housing. Again, use a little no. 2 grease to hold the seal in place.
5. Press bearing cone (7) onto king pin (10). Make sure the bearing cone is pressed on all the way, and is seated squarely.
6. Lift the frame of the machine high enough to allow installation of the king pin into the king pin housing. Weight of an empty machine at the front bolster group is approximately 2025 kg (4500 lbs.).
7. Block the frame at this height to prevent the frame from moving.
8. Move the front bolster group under the machine frame. Insert the king pin into the king pin housing. Weight of the front bolster group is approximately 432 kg (951 lbs.).
9. Carefully lower the frame to fully insert the king pin.
10. Press bearing cone (4) onto king pin (10) inside the king pin housing. Press the bearing cone far enough so that it fits in bearing cup (5).
11. Use a depth gauge to measure dimension (14). Dimension (14) is the distance from the top of bearing cone (4) to the top of king pin (10).
12. Install shims (3) to the top of king pin (10) so that dimension (14) is .51 to .76 mm (.020 to .030 in.).
13. Secure retainer plate (1) to king pin (10) with three bolts and washers.
14. Torque the three bolts to 75 N·m (55 lb. ft.).
15. Connect grease hose (9) to the grease fitting on plate retainer (1). Run a little grease through the hose to check for restrictions.
16. Connect water hose (13) to the inlet port of the front spray bar.
17. Connect the rod end of the steer cylinder to the front bolster group.
Disassemble Front Bolster Group
Start By:
a. remove front bolster group
b. remove hub and axle assemblies
1. Remove front spray bar and scraper assembly (2) from primary bolster (1).
2. Drive two roll pins (5) out of pivot pin (4). Remove two thrust washers (2) from pivot pin (4).
3. Drive pivot pin (4) out of king pin (3) and primary bolster (1).
4. Remove king pin (3) from primary bolster (1). Weight of king pin is approximately 28 kg (64 lbs.).
5. Note the positions of bushings (7) and (8) as the king pin is removed. Collect the bushings and save for reassembly.
6. Drive two roll pins (5) out of pivot pin (4). Remove two thrust washers (6) from the pivot pin.
7. Drive pivot pin (4) out of secondary bolster (9) and primary bolster (1).
8. Remove secondary bolster (9) from primary bolster (1). Weight of secondary bolster is approximately 46 kg (100 lbs.).
9. Examine all pivot pins (4) and roll pins (5). Bent, cracked, or badly worn pins must be replaced with new parts.
10. Check mounting holes and ears on primary bolster (1), secondary bolster (9), and king pin (3). Look for cracks, enlarged holes, or other structural damage in these components. Repair or replace any damaged items before assembly.
11. Check thrust washers (6) and bushings (7) and (8) for damage or excessive wear. Replace with new parts as necessary.
12. Clean all components thoroughly before assembly.
Assemble Front Bolster Group
1. Move secondary bolster (9) into place at primary bolster (1). Weight of secondary bolster is approximately 46 kg (100 lbs.).
2. Install pivot pin (4) through the mounting ears of the secondary bolster, and through the primary bolster.
3. Install one thrust washer (6) on each end of pivot pin (4).
4. Secure pivot pin (4) and thrust washers (6) with two roll pins (5).
5. Move king pin (3) into place on the primary bolster. Weight of king pin is approximately 28 kg (64 lbs.).
6. Insert bushings (7) and (8) between the mounting ears of king pin (3) and the primary bolster. Use enough bushings so that end play between the king pin and the bolster is no more than 1.5 mm (.060 in.). If only one bushing is needed, it must be placed toward the rear of the machine.
7. Install pivot pin (4) through the mounting ears of king pin (3), and through the primary bolster.
8. Install one thrust washer (6) on each end of pivot pin (4).
9. Secure pivot pin (4) and thrust washers (6) with two roll pins (5).
10. Install front spray bar and scraper assembly to the primary bolster.
End By:
a. install hub and axle assemblies
b. install front bolster group