Usage:
Introduction
This Special Instruction gives the procedure for installation of the lift cylinders and the 8A Bulldozer with or without dual tilt cylinders.
NOTE: Each section contains the related parts list.
After the assembly is complete, prepare the machine for service as shown in the machine's Operation & Maintenance Manual.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
Reference: Service Manual, Parts Manual and Operation & Maintenance Manual.
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Do not attempt to assemble this machine until you have read and understand the assembly instructions. Improper procedures could result in injury or death. |
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| NOTICE |
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Do not let any dirt or foreign material get into the hydraulic system during assembly or maintenance operation. Keep the oil in the hydraulic system at the correct level to prevent pump cavitation. |
Weights
| NOTICE |
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When a hoist is used to lift any part or assembly, stand clear of the area. Always make sure the hoist has the correct capacity. Approximate weights of the components are shown in the chart which follows. |
Shimming Procedure (Typical)
Typical Example
1. Remove all the shims from assembly (1).
2. Install assembly (1) and cap (2) on trunnion (3) without the shims. Tighten the bolts until snug using five percent of the specified joint torque or 50 N·m (37 lb ft), which ever is larger. Maintain equal distance on both (A) and (B) of cap (2).
3. Insert an equal amount of shims as needed into spaces (A) and (B), between the cap and the assembly.
NOTE: The number of shims at (A) must be equal to, or within one of the number of shims at (B). For example, if (A) has eight shims, (B) must have seven, eight or nine shims.
4. Add one additional shim to space (A) and one additional shim to space (B).
5. Tighten the cap to the proper torque.
6. This should allow the assembly to move on the trunnion freely and within the specified tolerance (0.25 mm minimum).
NOTE: It may be necessary to remove one or more shims after a short time of "Wear In" due to normal surface variations or paint thicknesses.
Installation of Lift Cylinders
Necessary Parts
NOTE: Clean all surfaces where parts are to be installed, including removal of paint from mating surfaces.
Installation Procedure for 8E6153 and 6I8788 Cylinder Mounting Groups
(C) 6Y5693 Yoke does not have this tang.
NOTE: Remove shipping covers and plugs from radiator guard housing.
1. Lubricate seal (1) with multipurpose type grease. Install seal (1) in radiator guard housing with the lips to the outside.
2. Pack cylinder group mounting bearing bores in radiator guard housing with multipurpose type grease.
3. Install yoke (2) in radiator guard housing. Lock yoke (2) in place with pin (3).
NOTE: Remove cover (A) and bolts (B) to install pin (3). Install cover (A) and bolts (B) after pin (3) is installed.
4. Install fitting (5) in radiator guard housing.
5. Pack cap assemblies (4) with multipurpose type grease.
6. Install cap assemblies (4) on trunnions of cylinder group (7).
7. Mount cylinder group (7) and cap assemblies (4) on yoke (2) with four bolts (6). Tighten bolts (6) to a torque of 430 ± 60 N·m (315 ± 44 lb ft).
8. Repeat Steps 1 through 7 for the other side of the machine.
NOTE: Steps 9 and 10 are for shipping purposes only.
9. Install plate (8) to radiator guard housing with washer (9) and bolt (10).
NOTE: To install plate (8) on the left side of the machine, use a bolt from the tilt cylinder lines group (manifold) that comes with the machine.
10. Assemble clips (11) and (12) to cylinder group (7) and plate (8) with two washers (9), bolt (13), and nut (14).
NOTE: For installation of the 6I9788 Cylinder Mounting Group, item (14) requires two washers and a nut.
11. Repeat Steps 9 and 10 for the other side of the machine.
NOTE: Remove shipping covers and seals from manifold on radiator guard housing and lift cylinders (7).
12. Install connector (15) to cylinder group (7) with seal (16).
13. Connect hose assembly (17) to connector (15) on cylinder group (7) with seal (18).
14. Install connector (19) to cylinder group (7) with seal (20).
15. Install tube assembly (21) to connector (19) with seal (22).
16. Connect hose assembly (23) to tube assembly (21) with seal (24), two flanges (25), two washers (26), and two bolts (27).
17. Install bracket assembly (28) to flanges (25) on tube assembly (21) with two washers (26) and two bolts (29).
18. Install plate assembly (30) to cylinder group (7) and bracket assembly (28) with six washers (31), four bolts (32), and two bolts (33).
19. Connect the other ends of hose assemblies (17) and (23) to manifold on radiator guard housing with two seals (24), four flanges, eight washers, and eight bolts.
NOTE: The items not numbered are part of the lines group that comes with the machine.
20. Install grommets (34) and (35) to hose assemblies (17) and (23) with spacer (36), washer (37), bolt (38), and locknut (39). Tighten bolt (38) to a torque of 8 ± 2 N·m (71 ± 18 lb in).
21. Repeat Steps 12 through 20 for the other side of the machine.
Installation of Trunnions
Necessary Parts
Installation Procedure
Typical Example
Starting on one side:
1. Remove shipping cover (1) from the track roller frame.
Typical Example
2. Remove plug (3) and move plate (2) in towards the center of the machine as far as possible. Install plug (3) back in the plate.
NOTE: Step 2 eliminates the hydraulic pressure that forms between seal plate (2) and pivot shaft retainer plate (A). This step also allows adequate clearance between trunnion assembly (4) and plate (2).
Typical Example
3. Install the guide pins [same thread size as bolts being installed, approximately 203 mm (8 in) in length] in the track roller frame.
Typical Example
4. Start trunnion assembly (4) on the guide pins.
Typical Example
5. Install trunnion assembly (4) with 16 washers (5) and bolts (6).
6. Tighten bolts (6) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
7. Repeat Steps 1 through 6 for other side of the machine.
Installation and Assembly of Bulldozer (Without Dual Tilt)
Necessary Parts
NOTE: All hardware is metric.
Installation and Assembly Procedure
NOTE: Before bolting the two frame assemblies together, clean the key slots for keys (4). The key slots must be free of all paint, rust, debris, or anything that can cause interference with the installation of keys (4). Keys (4) are a press fit and it is necessary to "drive them in" after most of the bolts are installed. Refer to Step 1 that follows.
1. Assemble frame assembly-RH (1) to frame assembly-LH (2). Install 30 bolts (5), 60 washers (3), and 30 nuts (6). Tighten bolts (5) just enough to put a small amount of pressure (torque) on them. install and drive into place the two keys (4) in the key slots of the frame assemblies.
Install the two additional bolts (5) with washers (3) and nuts (6) in the bolt holes in the area where keys (4) were installed. Tighten all bolts (5) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
2. Install pin (7) in frame assembly-RH (1) with retainer (8) and two bolts (9). Tighten bolts (9) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
3. Measure the height from the ground to the trunnion assembly on the roller frames.
4. Raise and block the rear of C-frame assembly (A) to the height measured in Step 3.
5. Move machine in position between C-frame assembly (A) and stop the engine.
6. Install C-frame assembly (A) to trunnion assembly with cap (10), shims (11), two bolts (12), and two nuts (13). Tighten bolts (12) to a torque of 1800 ± 200 N·m (1320 ± 150 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
7. Repeat Step 6 for the other side of the machine.
NOTE: Remove shipping plate and clips from radiator guard housing and the lift cylinder group, before connecting the lift cylinder group to C-frame assembly (A).
8. Connect the lift cylinder group to C-frame assembly (A) with cap, shims, four bolts, and nuts. Tighten bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of the lift cylinder group.
9. Repeat Step 8 for the other side of the machine.
10. Raise and block the bulldozer blade in an upright position.
11. Install arm assembly-RH (19) to bulldozer blade with pin (16), retainer (17), and two bolts (18). Tighten bolts (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
12. Install arm assembly-LH (20) to bulldozer blade with pin (16), retainer (17), and two bolts (18). Tighten bolts (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
Typical Example (earlier model shown)
13. Align C-frame assembly (A) with bulldozer blade and connect pin (7) to bulldozer blade with pin (14), retainer (15), and bolt (18). Tighten bolt (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
14. Assemble ballstud (21) to arm assembly-RH (19) with cap (22), shims (23), and four bolts (24). Tighten bolts (24) to a torque of 270 ± 40 N·m (200 ± 30 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
15. Install arm assembly-RH (19) with ballstud (21) to C-frame assembly (A) with pin (25) and pin (26).
16. Install brace group (27) to bulldozer blade with cap, shims, and four bolts and nuts. Tighten bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of the brace group.
(B) 1373.0 mm (54.05 in).
17. Adjust brace group (27) to dimension (B).
NOTE: Apply a heavy coating of multipurpose type grease to the threaded surfaces on brace group (27).
18. Assemble other end of brace group (27) to arm assembly-RH (19) with pin (28), retainer (29), and two bolts (30). Tighten bolts (30) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
19. Repeat Steps 14 through 18 for the left side of the machine.
20. Check oil in hydraulic tank and fill if necessary. Cycle cylinders full stroke in both directions to purge air from lines and cylinders. Refill hydraulic tank to full mark.
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Check clearance (C) between pin (7) and C-frame assembly (A). |
(C) 25 to 45 mm (1 to 1.8 in).
21. After the assembly is complete, get the machine ready for use as shown in the machine's Operation & Maintenance Manual.
Installation and Assembly of Bulldozer (With Dual Tilt)
Necessary Parts
NOTE: All hardware is metric.
Installation and Assembly Procedure
NOTE: Before bolting the two frame assemblies together, clean the key slots for keys (4). The key slots must be free of all paint, rust, debris, or anything that can cause interference with the installation of keys (4). Keys (4) are a press fit and it is necessary to "drive them in" after most of the bolts are installed. Refer to Step 1 that follows.
1. Assemble frame assembly-RH (1) to frame assembly-LH (2). Install 30 bolts (5), 60 washers (3), and 30 nuts (6). Tighten bolts (5) just enough to put a small amount of pressure (torque) on them. Install and drive into place the two keys (4) in the key slots of the frame assemblies.
Install the two additional bolts (5) with washers (3) and nuts (6) in the bolt holes in the area where keys (4) were installed. Tighten all bolts (5) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
2. Install pin (7) in frame assembly-RH (1) with retainer (8) and two bolts (9). Tighten bolts (9) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).
3. Measure the height from the ground to the trunnion assembly on the roller frames.
4. Raise and block the rear of C-frame assembly (A) to the height measured in Step 3.
5. Move machine in position between C-frame assembly (A) and stop the engine.
6. Install C-frame assembly (A) to trunnion assembly with cap (10), shims (11), two bolts (12), and two nuts (13). Tighten bolts (12) to a torque of 1800 ± 200 N·m (1320 ± 150 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
7. Repeat Step 6 for the other side of the machine.
NOTE: Remove shipping plate and clips from radiator guard housing and the lift cylinder group, before connecting the lift cylinder group to C-frame assembly (A).
8. Connect the lift cylinder group to C-frame assembly (A) with cap, shims, four bolts, and nuts. Tighten bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of the lift cylinder group.
9. Repeat Step 8 for the other side of the machine.
10. Raise and block the bulldozer blade in an upright position.
(B) 1190.0 ± 1.5 mm (46.85 ± .06 in).
11. Install tube assemblies (31) and (32) to blocks on bulldozer blade with four blocks (33), four washers (34), and four bolts (35). Tighten bolts (35) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
NOTE: Before tightening bolts (35), align tube assemblies (31) and (32) to dimension (B) from center line of bulldozer blade.
12. Install arm assembly-RH (19) to bulldozer blade with pin (16), retainer (17), and two bolts (18). Tighten bolts (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
13. Install arm assembly-LH (20) to bulldozer blade with pin (16), retainer (17), and two bolts (18). Tighten bolts (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
Typical Example (earlier model shown)
14. Align C-frame assembly (A) with bulldozer blade and connect pin (7) to bulldozer blade with pin (14), retainer (15), and bolt (18). Tighten bolt (18) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
15. Assemble ballstud (21) to arm assembly-RH (19) with cap (22), shims (23), and four bolts (24). Tighten bolts (24) to a torque of 270 ± 40 N·m (200 ± 30 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
16. Install arm assembly-RH (19) with ballstud (21) to C-frame assembly (A) with pin (25) and pin (26).
NOTE: Extend cylinder group (27) to approximately 1373 mm (54 in), from center of head end eye to center of rod end eye.
17. Install cylinder group (27) to bulldozer blade with cap, shims, four bolts, and nuts. Tighten bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft). See the topic entitled Shimming Procedure in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of the cylinder group.
18. Assemble other end of cylinder group (27) to arm assembly-RH (19) with pin (28), retainer (29), and two bolts (30). Tighten bolts (30) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
19. Repeat Steps 15 through 18 for the left side of the machine.
(D) Upper. (E) Lower.
20. Connect hose assemblies (36) to tube assemblies on the bulldozer blade with two seals (37), four flanges (38), eight washers (39), and eight bolts (40). Tighten bolts (40) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
(D) Upper. (E) Lower.
21. Connect the other end of hose assemblies (36) to the manifold on the radiator housing with two seals (37), four flanges (38), eight washers (39), and eight bolts (40). Tighten bolts (40) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
22. Connect hose assembly (41) to tube assembly (31) on bulldozer blade with seal (37), two flanges (38), four washers (39), and four bolts (40). Tighten bolts (40) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
23. Connect hose assembly (42) to tube assembly (32) on bulldozer blade with seal (37), two flanges (38), four washers (39), and four bolts (40). Tighten bolts (40) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
24. Connect hose assembly (41) to rod end of tilt cylinder with seal (37), two flanges (38), four washers (39), and four bolts (40). Tighten bolts (40) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
25. Connect hose assembly (42) to head end of tilt cylinder with seal (43), two flanges (44), four washers (34), and four bolts (35). Tighten bolts (35) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
26. Install bracket (45) to tilt cylinder with washer (46) and bolt (47). Tighten bolt (47) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
27. Install grommet (48) to hose assembly (42). Assemble clips (49) and (50) to grommet (48) and bracket (45) with bolt (51), two washers (52), and nut (53). Tighten bolt (51) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
28. Repeat Steps 22 through 27 for the other side of the machine.
29. Install guard assembly (54) to tilt cylinder-RH with two washers (52), two bolts (55), two washers (46), and two bolts (47). Tighten bolts (47) to a torque of 270 ± 40 N·m (200 ± 30 lb ft). Tighten bolts (55) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
30. Install guard assembly (56) to tilt cylinder-LH with two washers (52), two bolts (55), two washers (46), and two bolts (47). Tighten bolts (47) to a torque of 270 ± 40 N·m (200 ± 30 lb ft). Tighten bolts (55) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
31. Install guard assembly (57) to blocks on bulldozer blade with four washers (52) and four bolts (58). Tighten bolts (58) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
32. Check oil in hydraulic tank and fill if necessary. Cycle cylinders full stroke in both directions to purge air from lines and cylinders. Refill hydraulic tank to full mark.
| NOTICE |
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Check clearance (C) between pin (7) and C-frame assembly (A). |
(C) 25 to 45 mm (1 to 1.8 in).
33. After the assembly is complete, get the machine ready for use as shown in the machine's Operation & Maintenance Manual.