Usage:
Introduction
This Special Instruction gives the procedure for installation of the lift cylinders and the 8S and 8U Bulldozers with a single tilt cylinder.
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.
Additional Reference Article
To retrofit for the Three-Position Tilt Brace (option) see the following publication:
Special Instruction, SEHS9740, "Conversion To Three-Position Tilt Brace".
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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
Illustration 1.
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.
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Do not coat any fasteners with oil or grease prior to tightening, unless instructed to do so. |
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 8E-6153 and 6I-8788 Cylinder Mounting Groups
Illustration 2.
(C) 6Y-5693 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 370 ± 50 N·m (272 ± 37 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). Tighten bolt (10) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
NOTE: Install plate (8) on the left side of the machine, using 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). Tighten bolt (13) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
11. Repeat Steps 9 and 10 for the other side of the machine.
NOTE: For installation of the 6I-8788 cylinder mounting group, item (14) requires two washers and a nut.
Illustration 3.
NOTE: Remove shipping covers and seals from manifold on radiator guard housing and lift cylinders (7).
12. Install connector (15) with seal (16) to cylinder group (7).
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). Tighten bolts (27) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
17. Install bracket assembly (28) to flanges (25) on tube assembly (21) with two washers (26) and two bolts (29). Tighten bolts (29) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
18. Install plate assembly (30) to cylinder group (7) and bracket assembly (28) with six washers (31), four bolts (32) and two bolts (33). Tighten bolts (32) and (33) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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 6 ± 1 N·m (4 ± .74 lb ft).
21. Repeat Steps 12 through 20 for the other side of the machine.
Installation of Trunnions
Necessary Parts
Installation Procedure
Illustration 4.
Typical Example
Starting on one side:
1. Remove shipping cover (1) from the track roller frame.
Illustration 5.
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.
Illustration 6.
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).
Illustration 7.
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.
Illustration 8.
Typical Example
4. Start trunnion assembly (4) on the guide pins.
Illustration 9.
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 (180 ± 30 lb ft).
7. Repeat Steps 1 through 6 for other side of the machine.
Assembly and Installation of Bulldozer (With Single Tilt)
Necessary Parts
NOTE: All hardware is metric.
Assembly Procedure
Illustration 10.
Typical Example (earlier model shown)
1. Raise and block the bulldozer blade in an upright position.
Illustration 11.
Grind relief on boss (E).
NOTE: On some models the 8E-6155 bracket assembly (D) [on the right side of blade, at the tilt cylinder connection] used a boss (E) [on inside of 8e-6155 bracket assembly (D)] that had a small corner radius instead of a full round radius. See Illustration 11. If you have a boss (E) that has a small corner radius, grind relief (F) as shown in Illustration 11 to prevent interference between tilt cylinder rod eye and boss (E). If boss (E) is round, no grinding should be required.
Illustration 12.
2. Install connector assembly (1) to the bulldozer blade with pin (2), retainer (4) and two bolts (5). Tighten bolts (5) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
Illustration 13.
3. Install arm group (6) to the bulldozer blade with pin (7), retainer (8) and two bolts (9). Tighten bolts (9) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
4. Repeat Steps 2 and 3 for the other side of the machine.
Illustration 14.
5. On the right side, install cylinder group (12) to the bulldozer blade with pin (3), retainer (4) and two bolts (5). Tighten bolts (5) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
Illustration 15.
6. Install cylinder group (12) to right arm group (6) with pin (11), retainer (8) and two bolts (9). Tighten bolts (9) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
Illustration 16.
Screw Tilt Brace Version
(X) 1235 mm (48.6 in).
7. On the left side, install brace group (10) to the bulldozer blade with pin (3), retainer (4) and two bolts (5). Tighten bolts (5) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
NOTE: Adjust brace group (10) to neutral dimension (X) before installation to arm group.
NOTE: Do not adjust the brace beyond the extended position, [X = 1285.0 mm (50.59 in)]. Damage to the lift cylinder may occur if adjustment X is greater than [1285.0 mm (50.59 in)].
NOTE: Apply a heavy coating of multipurpose type grease to the threaded surfaces on brace group (10).
Illustration 17.
Screw Tilt Brace Version
8. Install brace group (10) to left arm group (6) with pin (11), retainer (8) and two bolts (9). Tighten bolts (9) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
Illustration 18.
Three-position Tilt Brace Version
8A. Install the bearing end of the brace assembly (2) to the bulldozer blade with pin (8), retainer (6) and two bolts (5). Tighten bolts (5) to a torque of 900 ± 100 N·m (662 ± 74 lb ft).
NOTE: Left push arm (6) has been modified for "Three-Position Tilt Brace Version" using bracket assembly (1), plate (3) and gusset (4). See Special Instruction SEHS9740, "Conversion To Three-Position Tilt Brace", for further information about modification.
Illustration 19.
Three-position Tilt Brace Version
8B. Align the brace assembly (2) to center hole (A) of bracket assembly (1) on left push arm (6) and insert pin (7). Fasten pin (7) with retainer (6) and two bolts (5). The center hole (A) of bracket assembly (1) is neutral position. Tighten bolts (5) to a torque of 900 ± 100 N·m (662 ± 74 lb ft).
Illustration 20.
9. Install link group (13) to the blade assembly with cap, shims, four bolts and four nuts. See the topic entitled "Shimming Procedure" in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of link group (13).
Illustration 21.
Typical Example (earlier model shown)
10. Install tube assembly (14) to cylinder group (12) with seal (15), four washers (16) and four bolts (17). Tighten bolts (17) to a torque of 60 ± 12 N·m (44 ± 9 lb ft). Secure tube assembly (14) to cylinder group (12) with washer (18) and bolt (19). Tighten bolt (19) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
Illustration 22.
11. Insert two hose assemblies (20) into link group (13).
NOTE: Assemble plates (21) with the part number visible.
12. Connect the hose assemblies on the blade end of the link group to the under side of plate (21) with two seals (15), four flanges (22), eight washers (23) and eight bolts (24). Tighten bolts (24) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
NOTE: Hardware on top of plate (21) can be started for later hose assembly installation.
Illustration 23.
(A) Rod end. (B) Head end.
13. Install plate (21) to the link group with four washers (18) and four bolts (25). Tighten bolts (25) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
14. Connect two hose assemblies (26) to plate (21) (blade end) with two seals (15), four flanges (22), eight washers (23) and eight bolts (24). Tighten bolts (24) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
15. Install the other ends of hose assemblies (26) to tilt cylinder (12) with two seals (15), four flanges (22), eight washers (23) and eight bolts (24). Tighten bolts (24) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
Illustration 24.
16. On the machine end of link group (13), connect the other ends of hose assemblies (20) to the under side of plate (21) with two seals (15), four flanges (22), eight washers (23) and eight bolts (24). Tighten bolts (24) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
NOTE: Hardware on top of plate (21) can be started for later hose assembly installation.
Illustration 25.
(A) Rod end. (B) Head end.
17. Install plate (21) to link group (13) with four washers (18) and four bolts (25). Tighten bolts (25) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
18. Connect hose assembly (27) and hose assembly (28) to plate (21) (machine end) with two seals (15), four flanges (22), eight washers (23) and eight bolts (24). Tighten bolts (24) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
Illustration 26.
19. Install guard (29) to the tilt cylinder group with four washers (30), two bolts (31) and two nuts (32). Tighten bolts (31) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
Illustration 27.
20. Install guard (33) to link group (13) (blade end) with four washers (30), two bolts (34) and two nuts (32). Tighten bolts (34) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
NOTE: Assemble bolts (34) with the bolt heads on the blade side.
Illustration 28.
21. Loosen two bolts (C) on each end of plate (21). Install guard (35) to the plate and link group (machine end) with two washers (18) and two bolts (19).
Tighten bolts (C) and (19) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
Installation Procedure
Illustration 29.
1. Block push arms (6) to the height of the machine trunnions (see arrows).
2. Move the machine into the push arms. Turn off engine.
Illustration 30.
3. Install cap on push arm (6) with shims, two bolts and two nuts. See the topic entitled "Shimming Procedure" in this Special Instruction for shimming instructions. Tighten bolts to a torque of 1800 ± 200 N·m (1324 ± 147 lb ft).
NOTE: The items not numbered are part of the push arm group.
4. Repeat Step 3 for the other side of the machine.
Illustration 31.
5. Install link group (13) to the machine trunnion (see arrow) with shims, cap, four bolts and four nuts. See the topic entitled "Shimming Procedure" in this Special Instruction for shimming instructions.
NOTE: The items not numbered are part of link group (13).
Illustration 32.
(A) Rod end. (B) Head end.
NOTE: Remove shipping covers from the working ports on the manifold.
6. Connect hose assembly (27) and hose assembly (28) to the manifold with two seals (15), four flanges, eight washers and eight bolts. Tighten bolts to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
NOTE: The items not numbered are part of the tilt cylinder lines group.
Illustration 33.
7. On each side, install lift cylinders (see arrow) to the bulldozer blade with cap, shims, four bolts and four nuts. 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.
8. 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.
9. After the assembly is complete, get the machine ready for use as shown in the machine's Operation & Maintenance Manual.