Field Assembly of 854K Wheel Dozer{7000, 7960} Caterpillar

Wheel Dozer:

854K (S/N: 2211-UP)

Introduction

This publication contains the installation information and assembly procedures that are required to assemble the above model when the machine is shipped to the field.

Show/hide table

Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

Show/hide table

Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Show/hide table

NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

Keep the oil in the hydraulic system at the correct level in order to prevent pump cavitation.

Clean all the surfaces before installing parts.

ReferenceParts Manual, SEBP4421 Operation and Maintenance Manual, SEBU8077 Service Manual, RENR8905

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

Do not order parts until you understand the information that is contained in this document.

Illustration 1	g01509114
854K Wheel Dozer

Components and Weights

Illustration 2	g00398585
Typical example of shipping by truck

• The machine (1) without axles has a weight of 49400 kg (108900 lb).

• The rear axle housing (2) has a weight of 6800 kg (14990 lb).

• The front axle housing (3) has a weight of 6500 kg (14330 lb).

Illustration 3	g01509154
Typical example of shipping by truck

• The upper cab (4) has a weight of 270 kg (595 lb).

• Each wheel and tire arrangement (5) has a weight of 3200 kg (7050 lb).

• The Rollover Protective Structure (ROPS) (6) has a weight of 2500 kg (5510 lb).

• The blade assembly has a maximum weight of 10750 kg (23700 lb).

• The push beam has a weight of 7085 kg (15620 lb).

Preparation for Assembly

1. Park the trailer with the machine in the center of a large level area that has a good hard surface. Engage the parking brakes of the truck and place wood blocks between the trailer wheels.

Show/hide table



Illustration 4	g01507555

2. Remove the panel near the top of the stepson the left side of the machine. The panel must be removed in order to install the rear axle assembly and the left rear tire. Place the panel aside for later installation.

Show/hide table



Illustration 5	g00115505
Blocking of the truck trailer

3. Position blocks under the front of the trailer. Lower the front of the trailer onto the blocks. Disconnect the neck of the trailer from the base of the trailer and remove the truck.

4. Remove all of the chains and the fasteners that hold the front of the machine on the trailer.

Installation of the Front Axle

Note: Perform the following installation procedure if the front axle is not installed.

Show/hide table



Illustration 6	g00115507
Typical example of the mounting surfaces for the front axle

1. Clean the mounting surfaces for the front axle under the front frame of the machine. Make sure that the machined surface is free of dirt.

Show/hide table



Illustration 7	g00115509
Mounting surfaces that are located on the front axle

2. Clean the mounting surfaces on the front axle housing. Make sure that the machined surface is free of dirt.

Show/hide table



Illustration 8	g00115511
Typical example

3. Use a spreader bar and cables to position the front axle housing (1) under the front frame of the machine.

4. Lift the front axle housing until the dowel pins engage into the holes in the front frame.

5. Use ten 6V-1734 Bolts (2) with 20 4K-0684 Washers (3) and with ten 3K-9770 Nuts (4) in order to secure each side of the front axle housing to the front frame. Tighten all of the bolts to a torque of 1800 ± 200 N·m (1325 ± 100 lb ft).

Installation of the Rear Axle

Note: Perform the following installation procedure if the rear axle is not installed.

1. Clean the mounting surfaces for the rear axle under the rear frame of the machine. Make sure that the machined surface is free of dirt.

2. Clean the mounting surfaces on the trunnions of the rear axle housing. Make sure that the machined surface is free of dirt.

Show/hide table



Illustration 9	g00268348
Typical example of installing the rear axle

3. Position the rear axle assembly (1) under the machine. Use a spreader bar and cables to lift the rear axle assembly into position. Lift the rear axle assembly until the dowel pins engage into the holes in the frame.

4. Use 16 142-7074 Bolts (2) and use 16 9M-2828 Hard Washers (3) in order to secure the rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

Show/hide table



Illustration 10	g00268349

5. Use six 142-7074 Bolts (4) and use six 9M-2828 Hard Washers (3) in order to secure the front rear axle trunnion to the rear frame. Tighten the bolts to a torque of 1150 ± 150 N·m (850 ± 110 lb ft).

Show/hide table



Illustration 11	g00268350

6. Place a wood block between the axle housing and the rear main frame on both sides of the machine. The wood blocks will prevent the rear axle from oscillating while you are working near the rear axle.

Installation of Front Drive Shaft, Front Brake Oil Lines, and Front Axle Oil Cooler Lines

Show/hide table



Illustration 12	g01488594

1. Connect front drive shaft (1) to the front differential. Install four 9X-6480 Bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

Show/hide table



Illustration 13	g01469267

2. Connect 315-4145 Tube As (3) to the port on the front of the axle.

Show/hide table



Illustration 14	g01488833
Left side of front axle (rear view) (4) 291-5621 Tube As (5) 6D-4246 Clip (6) 8F-8513 Clip (7) 5K-9660 Clip (8) 8R-8087 Spacer (9) 264-8088 Tube As (10) 7M-8798 Clip (11) 8T-4136 Bolt (12) 8T-4121 Hard Washer

Show/hide table



Illustration 15	g01488875
Inside front frame above front axle (4) 291-5621 Tube As (9) 264-8088 Tube As (13) 229-5371 Hydraulic Block Gp (14) 115-2516 Block (15) 291-5620 Tube As (16) 264-8087 Tube As

3. Connect one end of 291-5621 Tube As (4) to the left side of 229-5371 Hydraulic Block Gp (13). 291-5621 Tube As (4) is the left return line for the axle oil cooler.

4. Connect one end of 264-8088 Tube As (9) to 115-2516 Block (14). 264-8088 Tube As (9) is the left service brake line.

5. Connect the opposite end of 291-5621 Tube As (4) to the left brake housing. Connect the opposite end of 264-8088 Tube As (9) to the left brake housing.

6. Attach the tubes to the front frame. Use one 8F-8513 Clip (6), one 5K-9660 Clip (7), one 8T-4136 Bolts (11), one 8T-4121 Hard Washer (12), and one 8R-8087 Spacer (8) .

   Attach 6D-4246 Clip (5) and 7M-8798 Clip (10) to the tubes. Do not attach these clips to the axle at this time.

Show/hide table



Illustration 16	g01469812
Left side of front axle (rear view) (17) 1F-1609 Spacer (18) 5P-1076 Hard Washer (19) 8T-4648 Bolt (20) 8T-6466 Bolt (21) 7X-7729 Washer (22) 9R-2216 Boss (23) 230-7680 Guard As

7. Install 230-7680 Guard As (23) over the tubes. Use two 1F-1609 Spacers (17), two 5P-1076 Hard Washers (18), and two 8T-4648 Bolts (19) in order to secure the guard to the brake housing.

   Use 8T-6466 Bolt (20), 7X-7729 Washer (21), and 9R-2216 Boss (22) in order to secure the guard to the axle housing. Place boss (22) between the guard and the clips that were attached to the tubes in Step 6.

Show/hide table



Illustration 17	g01469268
Right side of front axle (rear view) (6) 8F-8513 Clip (10) 7M-8798 Clip (12) 8T-4121 Hard Washer (15) 291-5620 Tube As (16) 264-8087 Tube As (24) 6D-4244 Clip (25) 8T-4196 Bolt (26) 2S-4762 Clip

8. Install 264-8087 Tube As (16) and 291-5620 Tube As (15) on the right side of the front axle. 264-8087 Tube As is the right service brake line. 291-5620 Tube As is the right return line for the axle oil cooler.

9. Install 230-7679 Guard As over the tubes on the right side of the axle. Refer to Step 7.

Show/hide table



Illustration 18	g01469856
Front axle (rear view)

10. Connect front wiring harness (27) to the wiring harness for the temperature sensor on the axle. Use two 4D-8123 Clips (28) in order to secure the harness to the axle housing.

Show/hide table



Illustration 19	g01469908

11. Connect 317-5602 Hose As (29) to the port at the bottom of the differential.

Show/hide table



Illustration 20	g01469910

12. Install 237-4686 Plate (30) on the axle housing. Use two 7X-0389 Bolts and two 242-0315 Spacers in order to install the plate.

Installation of Rear Drive Shaft, Rear Brake Oil Lines, and Rear Axle Oil Cooler Lines

Show/hide table



Illustration 21	g00268356

1. Connect the rear drive shaft (1) to the rear differential. Install four 9X-6480 Bolts (2) into the yoke assembly. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

Show/hide table



Illustration 22	g01471418
Front trunnion (top view) (3) 313-4443 Axle Harness (4) 5P-9085 Clip

Show/hide table



Illustration 23	g01509157
Rear axle (front view) (3) 313-4443 Axle Harness (4) 5P-9085 Clip (5) 4D-8123 Clip (6) 288-8390 Temperature Sensor Gp

2. Connect 313-4443 Axle Harness (3) to temperature sensor (6). Refer to Illustration 22 and Illustration 23 for the routing of the harness.

   Note: Make sure that a sufficient length of the harness is between clip (A) and clip (B). This verification will ensure that the harness is not stretched when the axle oscillates.

Show/hide table



Illustration 24	g01471454
Rear axle (front view) (7) 315-4138 Hose As (8) 229-5373 Hydraulic Block Gp (9) 314-7943 Hose As (10) 115-2516 Block (11) 282-3255 Tube As (12) 317-5414 Hose As

3. Connect 314-7943 Hose As (9) to 115-2516 Block (10) .

4. Connect 315-4138 Hose As (7) to 229-5373 Hydraulic Block Gp (8) .

5. Connect 282-3255 Tube As (11) to the top of the front trunnion support.

6. Connect 317-5414 Hose As (12) to the axle housing.

Show/hide table



Illustration 25	g01471456
Rear axle (rear view) (13) 282-3252 Tube As (14) 275-7769 Hose As

7. Connect 282-3252 Tube As (13) to the top of the rear trunnion.

8. Connect 275-7769 Hose As (14) to the top of the rear axle.

Installation of the Tires and Removal of the Truck Trailer

Show/hide table



Illustration 26	g01489274

1. Install two 138-8698 Rods into one of the wheels on the rear axle. The rods will be used in order to help guide the tire and rim onto the wheel.

Show/hide table



Illustration 27	g00115530
Typical example of installing a tire and rim

2. Use a hoist and use a sling in order to install the rear tires. The valve stem should be facing outward when the tires are installed. Install a 2J-3507 Full Nut with a 5P-8250 Washer onto each of the rods in order to hold the tire and rim assembly in place.

Show/hide table



Illustration 28	g00115531
Typical example

3. Install 46 9X-8898 Bolts (1) with 5P-8250 Washers (2) in the rim assembly. Tighten all of the bolts to a torque of 1152 N·m (850 lb ft).

4. Repeat Step 1 through Step 3 for the remaining rear tire.

Show/hide table



Illustration 29	g01509265
Lift eyes on front frame

5. Attach lifting cables to the two lifting eyes on the front frame. Attach the crane to the lifting cables and raise the machine. See the section on components and weights for machine weight. The machine must be high enough to remove the truck trailer from the machine.

6. Remove the truck trailer from the machine.

Show/hide table



Illustration 30	g01508013
The frame on stands

7. Place appropriate stands (4) or cribbing under frame (3) of the machine. The machine with the beam has an approximate weight of 69800 kg (153900 lb) without tires.

Show/hide table



Illustration 31	g01507555

8. Reinstall the panel on the left side of the machine.

Installation of the Beam and the Front Tires

1. Remove the bars and the plates in order to install the 153-7954 Beam .

2. Remove the shipping covers from the ends of the beam.

Show/hide table



Illustration 32	g01689657
The arrow indicates the front of the machine. Top view of the front frame and 153-7954 Push Beam (1) Front of beam (2) Rear of beam (3) Front frame (4) Hitch

Show/hide table



Illustration 33	g00400779

Note: The beam must be installed in the correct direction.

3. Make sure that taper (1) that is on the 153-7954 Push Beam is toward the front of the machine. The beam has a weight of 7094 kg (15640 lb).

4. Install lift eyes on the beam or wrap an appropriate chain around the beam.

5. Use an appropriate lifting device to position the beam to the side of frame (6). Remove any lift eyes from the beam.

6. Pull the beam through the holes that are provided in the frame of the machine. Trim the holes if the beam is oversize. Do not trim the bottom or the back of the holes.

7. Slide the beam to the rear of holes (5) that are located in frame (6) .

8. Make sure that the ends of the beam are an equal distance from the sides of the frame.

9. Clean the welding area 12.0 mm (0.50 inch) from the mating surfaces.

10. Preheat the tower to 125° ± 25°C (258° ± 45°F). Preheat 75.0 mm (3.0 inch) from the mating surfaces.

    Note: Temperature readings should be made 75.0 mm (3.0 inch) from the mating surfaces.

11. Preheat the beam to 50°C (120°F). Preheat 75.0 mm (3.0 inch) from the mating surfaces.

    Note: Maintain the temperature during welding in order to minimize embrittlement.

Show/hide table



Illustration 34	g00400798
Installation of the bars and plates

12. Install bars (8) and plates (7), as shown.

Note: Fillet welds should not exceed a size that is greater than 8.0 mm (0.32 inch).

Note: The finished welds should not exceed a size that is greater than 12.0 mm (0.50 inch).

Note: The maximum interpass temperature should not exceed 200°C (392°F).

Note: Welding wire must be of a low hydrogen type.

Show/hide table



Illustration 35	g00402738
Welding of the beam

13. Weld three fillet welds (10) in order to attach the beam to the square bar and the square bar to the frame. Completely weld all of the bars and plates.

    Note: Weld bead (9) on top of the three fillet welds is for appearance.

14. Paint the welded areas of the beam and the frame in order to prevent corrosion.

15. Repeat Steps 9 through 14 for the other side of the beam and frame.

16. Install the front tires. Follow the procedure in ""Installation of the Tires and Removal of the Truck Trailer" ". Follow steps 2 and Step 3 in order to install both of the front tires on the machine.

Installation of the Trunnion and the Adapter Plate

Show/hide table



Illustration 36	g00400618
Installing the adapter plate

1. Attach an eyebolt (1) and a suitable lifting device to 153-7955 Adapter Plate (2). Align the holes in the adapter plate with the holes in 153-7954 Push Beam .

2. Attach the adapter plate with 14 7L-9198 Bolts (3). Tighten the bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft).

Show/hide table



Illustration 37	g00400678

3. Install a suitable lifting device to 107-7523 Trunnion Assembly (4). Align the trunnion with the adapter plate.

4. Attach the trunnion to the adapter plate with12 7X-0406 Bolts (5). Tighten the bolts to a torque of 900 ± 100 N·m (660 ± 75 lb ft).

5. Repeat Steps 1 through 4 for the other end of the beam.

Installation of the Cab

Show/hide table



Illustration 38	g01463698

1. Ensure that 4E-6510 Seal (A) is located on the bottom portion of the cab. Ensure that 4E-6509 Seal (B) is located on the bottom portion of the cab. Ensure that two 256-2454 Seals (C) are located on the bottom portion of the cab.

Show/hide table



Illustration 39	g00888746

Show/hide table



Illustration 40	g00889805

2. Remove two nuts (1) and the washers from each side of the cab.

3. Install 9U-2670 Handhold (2) to the right side of the cab with two nuts (1) and the washers.

4. Install 9U-1301 Handhold (3) to the left side of the cab with two nuts (1) and the washers.

Show/hide table



Illustration 41	g00892110

5. Route wires (4) and (5) for the antennas toward the front of the cab for later connection to the ROPS.

Show/hide table



Illustration 42	g01473112

6. Install 219-8090 Suspension Seat Gp (6) and seat supports (7 ) and (10) in the cab with four 168-4510 Bolts (8) and with four 8T-4121 Hard Washers (9) .

Show/hide table



Illustration 43	g01508205

7. Attach the armrests to the seat supports. Use two 211-4942 Knob As in order to secure each armrest.

Show/hide table



Illustration 44	g00117913

Note: Remove the front instrument panel and lay the instrument panel on the floor of the cab. Removing the instrument panel will prevent the instrument panel from being hit and being damaged when the top of the cab is lowered into position.

Show/hide table



Illustration 45	g00444024

8. Attach an appropriate lifting device to the four brackets that are located on the top of the cab.

Show/hide table



Illustration 46	g01473136

9. Lift the top portion of the cab into position over the bottom portion of the cab. Slowly lower the top of the cab into position. There are three dowel pins (D) which are used to line up the top portion of the cab with the bottom portion of the cab.

   Note: The top portion of the cab will need to be guided into position onto the bottom portion of the cab.

Show/hide table



Illustration 47	g01473193
Front of the cab

Show/hide table



Illustration 48	g01473194
Rear of the cab

10. Secure the top portion of the cab with 20 8T-4196 Bolts (12) and with 20 8T-4221 Hard Washers (11) that are located around the platform.

Show/hide table



Illustration 49	g01473213

11. Connect the wiring harness (14) between the top portion of the cab and the bottom portion of the cab. Connect the tube for the washer fluid to the front wiper motor (13).

Show/hide table



Illustration 50	g01473216

12. Reinstall the front instrument panel with four 9X-2046 Screws (15) .

Show/hide table



Illustration 51	g01473233

13. Connect electrical connector (16) that is located near the right rear corner of the cab.

14. Connect hose assembly (17) that is located near the right rear corner of the cab to the rear window wiper.

15. Install the right side control panel.

Show/hide table



Illustration 52	g01473237

16. Install 123-8725 Insulation (18) over the right rear inside post of the cab.

17. Install two 7T-4306 Louver As (19) into insulation (18) .

    Note: In order to install louver assemblies (19), the fabric that covers the openings in the louver will need to be cut.

Show/hide table



Illustration 53	g01508762

18. Install 4E-7205 Seal (21) around the bottom of 123-8722 Duct (20) prior to installing the duct.

Show/hide table



Illustration 54	g01473241

19. Install duct (20) behind the seat. Secure duct (20) with six 8T-4189 Bolts (22) and six 8T-4896 Washers .

20. Install 103-2543 Seal (23) on duct (20) on the contact surface for the air filter.

Show/hide table



Illustration 55	g01473372

21. Install 9X-8216 Air Filter (24) in the opening of duct (20) .

Show/hide table



Illustration 56	g01473373

22. Install 4E-7204 Cover As (27) with two 7K-3262 Screws (25) and two 2R-2376 Washers .

23. Install two 8T-5027 Nuts (26) and two 9X-2045 Screws in order to plug the unused holes.

Show/hide table



Illustration 57	g01473374

24. Install 123-8724 Insulation (28) over the left rear inside post of the cab.

25. Install 6V-8928 Coat Hook (31) with one 9X-2042 Screw (29) .

26. Install 3E-6389 Dome Lamp (30) onto insulation (28) with three 9X-1046 Screws .

Show/hide table



Illustration 58	g01492493

27. Install 251-4646 Headliner (33) at the top of the door frame. Use three 8T-5027 Nuts (26) and three 111-4627 Screws (32) in order to install the headliner.

Show/hide table



Illustration 59	g01492853

28. Install 251-4645 Rear Panel (34) at the rear of the door frame. Use three 8T-5027 Nuts (26) and three 111-4627 Screws (32) in order to install the rear panel.

Show/hide table



Illustration 60	g01493073

29. Install 251-6492 Strip (35) at the bottom of the door frame. Use six 9X-2042 Screws (36) in order to install the strip.

30. Install the floor mat in the cab.

Show/hide table



Illustration 61	g01473375

31. Install 123-8721 Duct (38) over the vent of the existing air duct (E) .

32. Install 090-4808 Seal (37) around the top opening of 123-8721 Duct (38) .

Show/hide table



Illustration 62	g01473376

33. Install 213-4262 Seal (39) on the mating surface of the lower duct that is located on the right-hand side of the cab.

Show/hide table



Illustration 63	g00900567

34. Verify that the seals are in place on the 138-8630 Duct .

Show/hide table



Illustration 64	g01473377

35. Install 138-8630 Duct (41) .

36. Install four 8T-4196 Bolts (40) and four 8T-4121 Hard Washers .

37. Install two 8T-5027 Nuts (26) and two 9X-2045 Screws on duct (41) in order to plug the unused holes.

Show/hide table



Illustration 65	g01473378

38. Install 4E-9640 Handle (45) .

39. Install two 8T-4183 Bolts (44) and two 8T-4223 Hard Washers in order to secure the handle.

40. Install three 8Y-6352 Louver As (42) .

41. Install ten 8Y-6388 Louver As (43) with 20 104-2091 Flat Head Screws .

Show/hide table



Illustration 66	g01473379
Cover over right side control panel

42. Install 205-3076 Cover As (47) with three 9X-2042 Screws (46) .

43. Install 5L-6766 Plug (48) in the hole in the cover.

Show/hide table



Illustration 67	g01473382

44. Remove three bolts (49), the washers, and channel (50) .

Show/hide table



Illustration 68	g01509193

45. Connect tube assemblies (51) and (52) .

46. Connect electrical connector (53) .

47. Install 8T-4191 Bolt (54), 8T-4121 Hard Washer , 4K-8864 Clip , 5P-9297 Clip , and 7N-3718 Clip .

48. Install channel (50), three bolts (49), and the washers.

49. Refer to Step 50 and Step 51 if the machine is equipped with the 267-8836 Camera Ar . If the machine is not equipped with the 267-8836 Camera Ar , continue to ""Installation of the Steps and the Handholds" ".

Show/hide table



Illustration 69	g01509160

50. Mount 251-4157 Display Module Gp (55) on upper right door post.

51. Connect the electrical connector for the camera to the rear of the front display.

    Note: Refer to Parts Manual, SEBP4421, "854K Wheel Dozer" for details of the 252-9529 Camera Mounting Gp and the 282-4890 Camera Wiring Gp .

Installation of the Steps and the Handrails

Show/hide table



Illustration 70	g01496753
Rear left-hand side of machine

1. Install 355-9649 Step Group (5) on the left rear side of the machine. Use four 8T-4194 Bolts (3) with four 5P-1076 Hard Washers (4) to attach the step group.

2. Install 300-6344 Handle (1) on the left rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4).

3. Install 300-6343 Handle (2) on the left rear bumper. Secure the handle with four 8T-4194 Bolts (3) and four 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 71	g01473387
Rear right-hand side of machine

4. Install 355-9649 Step Group (5) on the right rear side of the machine. Use four 8T-4194 Bolts (3) with four 5P-1076 Hard Washers (4) to attach the step group.

5. Install 300-6344 Handle (1) on the right rear bumper. Secure the handle with four 8T-4194 Bolts (3) and four 5P-1076 Hard Washers (4) .

6. Install 300-6343 Handle (2) on the right rear bumper. Secure the handle with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 72	g01854581
Left-hand platform access

7. Install 325-7352 Handrail Assembly (10) on the step assembly. Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

8. Install 325-7350 Handrail Assembly (7). Secure the handrail assembly with four 8T-4139 Bolts (11) and four 8T-4223 Hard Washers (12) .

9. Connect 325-7352 Handrail Assembly (10) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

Show/hide table



Illustration 73	g01856353
Left-hand platform

10. Install 325-7347 Handrail Assembly (13). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

11. Connect 325-7347 Handrail Assembly (13) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

Show/hide table



Illustration 74	g01856354
Left-hand front platform

12. Install 325-7349 Handrail Assembly (14). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

13. Connect 325-7349 Handrail Assembly (14) to the 325-7347 Handrail Assembly (13). Connect the handrails with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

Show/hide table



Illustration 75	g01473391

14. Install 301-5792 Handhold Assembly (15). Secure the handhold assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 76	g01854536

15. Install 301-5791 Handrail Assembly (49). Secure the handrail assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 77	g01854553
Right-hand side of machine

16. Install 325-7351 Handrail Assembly (20) on the step assembly. Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

17. Install 325-7350 Handrail Assembly (7). Secure the handrail assembly with four 8T-4139 Bolts (11), and four 8T-4223 Hard Washers (12) .

18. Connect 325-7351 Handrail Assembly (20) to the 325-7350 Handrail Assembly (7). Connect the handrails with one 8T-4195 Bolt (8) , two 7X-7729 Washer (9), and one 8T-4133 Nut (46) .

19. Install 325-7346 Handrail Assembly (17). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

20. Connect 325-7346 Handrail Assembly (17) to the 325-7350 Handrail Assembly (7) with one 8T-4195 Bolt (8), two 7X-7729 Washers (9), and one 8T-4133 Nut (46) .

21. Install 325-7348 Handrail Assembly (18). Secure the handrail assembly with six 8T-4139 Bolts (11) and six 8T-4223 Hard Washers (12) .

22. Install 325-7353 Gate Assembly (16). Secure the handrail assembly with two 323-3747 Brackets (45) with four 8T-4195 Bolts (8) and four 8T-4121 Hard Washer (44) to 325-7346 Handrail Assembly (17).

23. Secure 323-3746 Brackets (50) with four 8T-4195 Bolts (8) and four 8T-4121 Hard Washer (44) to 325-7353 Gate Assembly (16).

24. Secure 323-3749 Bracket (39) with two 8T-4195 Bolts (8) and two 8T-4121 Hard Washers (44) to 325-7353 Gate Assembly (16) .

25. Secure gate assembly with two 8T-6466 Bolts (40), two 127-0366 Spacers (41), two 161-3357 Spacers (42), four 7X-7729 Washers (9), and two 096-4883 Locknuts (43) .

26. Confirm easy outward opening of the gate.

27. Secure the 300-4511 Latch Assembly (35) to the 325-7348 Handrail Assembly (18) with two 248-0102 U-Bolts (36), four 8T-4224 Hard Washers (37), and four 5C-7261 Nuts (38). The latch assembly must be assembled in a way that allows the latch rod to go through the hole of the 323-3749 Bracket (39). Bracket (39) is attached to the gate assembly.

Show/hide table



Illustration 78	g03490817
(35) 300-4511 Latch As (K) 25 mm (0.98 inch)

28. Orient Latch As (35) for proper assembly and clearance. Refer to Illustration 78.

29. Install 325-7354 Ladder Assembly (19) on the right side of the machine. Secure the ladder assembly with four 8T-4183 Bolts (6) and four 5P-1076 Hard Washers (4) .

30. Assemble two 323-3748 Belts (34) with two 4V-9803 Plates (31), four 8T-4184 Bolts (33), and four 6V-7687 Locknuts (32). Refer to Illustration 77.

31. Assemble four 325-7233 Bracket Assemblies (47) to the 323-3748 Belts (34). Install the bracket assemblies with four 4V-9802 Bar (27), eight 8T-4138 Bolts (29), and four 6V-7687 Locknuts (32). Refer to Illustration 77.

32. Assemble two 323-3751 Step Assemblies (20) on the 325-7233 Bracket Assemblies (47). Secure the step assemblies with four 5P-2228 Bolts (28), four 8T-4223 Hard Washers (12), and four 8F-6437 Washers (30). Refer to Illustration 77.

33. Install rubber mounted steps to the bottom of the ladder assembly.

34. Install 301-5791 Handrail Assembly (14). Secure the handrail assembly with six 8T-4183 Bolts (6) and six 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 79	g01854560
Left-hand side of platform

35. Install the 325-7381 Toe Guard (21). Secure toe guard with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4). Refer to Illustration 79.

36. Install 325-7378 Toe Guard (22) with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4) .

37. Install 325-7380 Toe Guard (23). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers

Show/hide table



Illustration 80	g01854561
Right-hand side of platform

38. Install 325-7381 Toe Guard (21). Secure toe guard with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4). Refer to Illustration 80.

39. Install 325-7377 Toe Guard (26). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4). Refer to Illustration 80.

40. Install 325-7382 Toe Guard (25). Secure toe guard with three 8T-4192 Bolts (48) and three 5P-1076 Hard Washers (4). Refer to Illustration 80.

41. Install 325-7379 Toe Guard (24). Secure toe guard with six 8T-4192 Bolts (48) and six 5P-1076 Hard Washers (4). Refer to Illustration 80.

Show/hide table



Illustration 81	g01857694
Walkway for the cab

42. Assemble 237-7952 Sheet Assembly (51) with 249-0926 Platform (52) and 249-0927 Platform (53). Secure platforms with eight 7X-7729 Washer (9) and eight 8T-4195 Bolts (8) .

43. Install 325-7356 Handrail Assembly (54). Secure handrail assembly with four 8T-4139 Bolts (11) and four 8T-4223 Hard Washers (12) .

44. Install 325-7357 Handrail Assembly (55). Secure handrail assembly with four 8T-4139 Bolts (11) and four 8T-4223 Hard Washers (12) .

45. Install 325-7358 Handrail Assembly (56). Secure handrail assembly with four 8T-4139 Bolts (11) and four 8T-4223 Hard Washers (12) .

46. Install 325-7383 Guard Plate (57). Secure guard plate with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4) .

47. Install 325-7384 Guard Plate (58). Secure guard plate with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4) .

48. Install 325-7385 Guard Plate (59). Secure guard plate with four 8T-4192 Bolts (48) and four 5P-1076 Hard Washers (4) .

Show/hide table



Illustration 82	g01858093
The walkway bolted to the cab.

49. Assemble the walkway to the cab. Secure the walkway with eight 8T-4195 Bolts (8) and eight 8T-2561 Hard Washers (60) .

Show/hide table



Illustration 83	g02455182
View of rear guardrails

50. Install 350-7160 Guardrail As (61) to the right rear side of the machine. Secure guardrail (61) to the side of the machine with four 8T-4139 Bolts (11) and four 7X-3392 Hard Washers (63). Secure guardrail (61) to the rear of the machine with two 8T-4139 Bolts and two 5P-1076 Hard Washers (4). Refer to Illustration 83.

51. Install 350-7161 Guardrail As (62) to the left rear side of the machine. Secure guardrail assembly using Step 50. Refer to Illustration 83.

Installation of Product Link (if equipped)

Show/hide table



Illustration 84	g01500914
(1) 263-9088 Communication Electronic Control Module (2) 290-2227 Plate As (3) 6V-8490 Bolt (4) 9X-8256 Washer

1. Attach 263-9088 Communication Electronic Control Module (1) to 290-2227 Plate As (2). Use four 6V-8490 Bolts (3) and four 9X-8256 Washers (4) in order to connect the module to the plate. Tighten the bolts to a torque of 3.5 ± 1.0 N·m (30 ± 9 lb in).

Show/hide table



Illustration 85	g01500915

2. Mount the plate with the communication ECM to the underside of the ROPS. Use two 8T-4121 Hard Washers and two 8T-4136 Bolts in order to mount the plate to the canopy. Connect the ROPS wiring to the communication ECM.

Show/hide table



Illustration 86	g01500916
Left side of ROPS canopy (5) 270-8544 Bracket As (6) 8T-4137 Bolt (7) 8T-4121 Hard Washer

3. Attach 270-8544 Bracket As (5) to the left side of the ROPS canopy. Use two 8T-4137 Bolts and two 8T-4121 Hard Washers in order to attach the bracket.

Show/hide table



Illustration 87	g01500917
Left side of ROPS canopy (8) 310-2391 Antenna As (9) 9X-6772 Cable Strap (10) 4P-7581 Clip

4. Attach 310-2391 Antenna As (8) to the 270-8544 Bracket As . Tighten the nut on the antenna to 5.0 ± 0.5 N·m (44 ± 4 lb in). Attach 4P-7581 Clip (10) to the bracket. Use one 9X-6772 Cable Strap (9) in order to strap the antenna cable to the clip. Use an additional cable strap in order to strap the cable to the link on the underside of the bracket.

5. Attach the antenna cable to the communication ECM. Use cable straps in order to strap the cable to the underside of the ROPS canopy.

Installation of the ROPS

Show/hide table



Illustration 88	g00118009

Show/hide table



Illustration 89	g00118010

1. Remove 113-6026 Cover (1) from the right side of the platform and remove 113-6027 Cover (2) from the left side of the platform. In order to install the ROPS, the pictured cover assemblies are to be removed.

Show/hide table



Illustration 90	g00382992
Typical example

2. Install three lifting eyes onto the top of the ROPS. Use the three holes that are provided in the top of the ROPS. Attach a crane to the ROPS.

   Note: Protect the wiring harnesses, that are located on the ROPS, when the ROPS is being installed.

Show/hide table



Illustration 91	g00444133

3. Clean the ROPS mounting surface on the machine and on the ROPS.

Show/hide table



Illustration 92	g00383033
Typical example

4. Use a crane to lift the ROPS into position over the top of the cab.

   Note: The ROPS will need to be guided into position on the machine.

Show/hide table



Illustration 93	g01493613

Note: Apply oil to the threads of all bolts for the ROPS before installation. Failure to apply oil can result in improper bolt torque.

5. Secure the ROPS with 20 8C-3236 Bolts (3) and 20 3S-7023 Washers (4) on each side of the ROPS. Tighten the bolts to a torque of 1600 ± 200 N·m (1200 ± 150 lb ft).

6. Reinstall 113-6026 Cover Assembly (1) on the right side of the platform. Reinstall 113-6027 Cover Assembly (2) on the left side of the platform.

Show/hide table



Illustration 94	g01473380

7. Connect the wiring harness on the right ROPS post to the wiring harness on the machine.

Installation Of The Lights, Mirrors, Exhaust Stacks, and Antennas

Illustration 95	g02342759

1. Place 292-2323 Film (1) onto 302-5176 Cover (2) .

   Note: Wet the back side of the film before placing the film on any surface. Wetting the film will enable the film to be moved after the film has been placed on the surface. The water that is behind the film must be removed. Apply pressure to the film in order to remove the water.

2. Install 302-5176 Cover (2) onto the top rear of the ROPS.

Show/hide table



Illustration 96	g02342770

3. Install 9X-9365 Bracket (3) onto the left and right side of the top rear of the ROPS. Use two 8T-4121 Hard Washers (4) and two 8T-4137 Bolts (5) in order to secure the bracket.

4. Connect the wire harnesses to 353-2833 Flood Lamp Gp (12). Mount one flood lamp to each bracket assembly with one 8T-4195 Bolt (6), one 8T-4122 Hard Washer (7), 8T-4133 Nut (8), two 7X-7729 Hard Washers (9), 099-5307 Grommet (10) and 353-2835 Mounting Bracket As (11) .

5. Torque the bolt to 35 N·m (26 lb ft).

Show/hide table



Illustration 97	g02342458

6. Connect the wire harness to each 353-2833 Flood Lamp Gp (12). Mount one floodlight on the left front corner of the ROPS. Mount one floodlight on the right front corner of the ROPS. Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), 7X-7729 Hard Washer (9) and 8T-4195 Bolt (6) .

Show/hide table



Illustration 98	g02342846

7. Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the right rear side of the radiator guard with 4E-8976 Bracket (14). Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6) .

Show/hide table



Illustration 99	g02342855

8. Connect the wire harness to each 353-2834 Flood Lamp Gp (13). Mount one floodlight on the left rear side of the radiator guard with 4E-8975 Bracket . Mount each floodlight with one 353-2835 Mounting Bracket As (11), 099-5307 Grommet (10), two 7X-7729 Hard Washers (9), 8T-4133 Nut (8), three 8T-4122 Hard Washers (4) and three 8T-4195 Bolt (6) .

Show/hide table



Illustration 100	g02342940

9. Place 292-2322 Film (16) onto 9U-3663 Plate Assembly (17) .

   Note: Wet the back side of the film before placing the film on any surface. Wetting the film will enable the film to be moved after the film has been placed on the surface. The water that is behind the film must be removed. Apply pressure to the film in order to remove the water.

10. Mount 9U-3663 Plate Assembly (17) onto the front of the ROPS with five 6V-3822 Bolts (19) and five 6V-5839 Washers (20) .

Show/hide table



Illustration 101	g02342943

11. Install 164-1990 Bracket Assembly (21) onto the right side of the ROPS and install 315-3461 Bracket Assembly onto the left side of the ROPS. Secure each bracket assembly with four 8T-4184 Bolts (22) and four 198-4778 Hard Washers (23) .

Show/hide table



Illustration 102	g02342958

12. Attach two 126-7222 Angles (28) to each bracket assembly. Use one 8T-4136 Bolt with one 7X-7729 Washer in order to assemble each angle to the bracket.

13. Mount one 5P-6879 Mirror (27) to the angles on each bracket assembly. Secure each mirror with two 8T-4136 Bolts (26), with two 7X-7729 Washers (25) and with two 6V-7744 Locknuts (24) .

Show/hide table



Illustration 103	g02342960
Installation of right side mirror (29) 5P-6879 Mirror (30) 6K-5290 Clip (31) 6K-5291 Clip (32) 5P-7468 Clip (33) 5P-7469 Clip (34) 6V-1874 Grommet (35) 7X-0563 Hard Washer (36) 7X-7729 Washer (37) 8T-0389 Locknut (38) 8T-4185 Bolt (39) 8F-0492 Spacer (40) 8T-4195 Bolt (41) 7U-1903 Support

14. Install mirrors on the handrails on each side of the cab. Refer to Illustration 103.

Show/hide table



Illustration 104	g02342982

15. Install 324-0147 Step Assembly (42) on the lower right front of the cab. Install 324-0146 Step Assembly on the lower left front of the cab. Secure each step assembly with two 8T-4195 Bolts (43) and two 8T-4121 Washers (44) .

Show/hide table



Illustration 105	g02342996

16. Position the exhaust stacks (45) over the holes in the hood. Secure the exhaust stacks to the top of the hood. Use four 8T-4183 Bolts (46) and four 5P-1076 Hard Washers on each exhaust stack.

Show/hide table



Illustration 106	g01690893
Front view of ROPS

Show/hide table



Illustration 107	g02343000
View of area (A) and area (B) .

17. Attach 9U-2330 Antenna Mount (48) to the ROPS. Attach 9U-2331 Antenna Assembly (47) to 9U-2330 Antenna Mount (48) .

18. Attach 9U-2330 Antenna Mount (50) to the ROPS. Attach 9U-2332 Citizens Band Antenna Assembly (49) to 9U-2330 Antenna Mount (50) .

HID Lights (If Equipped)

Show/hide table



Illustration 108	g02342877

1. Connect the wire harness to each 347-9427 Flood Lamp Gp (1) and 332-9402 Flood Lamp Gp (2). Mount flood lamps (1) and (2) to the top left and right corners of the ROPS. Mount both the left and right side floodlights with 373-1524 Bracket (3), two 7X-7729 Washers (4) and two 8T-4195 Bolts (5). Repeat this step on the opposite side of the machine.

Show/hide table



Illustration 109	g02342897

2. Connect the wire harness to each 347-9427 Flood Lamp Gp (1). Mount flood lamp (1) to the top left and right corners of the radiator guard. Mount the right side floodlight with 283-9815 Bracket (7), four 8T-4121 Washers (6) and four 8T-4195 Bolts (5) .

Show/hide table



Illustration 110	g02342917

3. Connect the wire harness to each 347-9427 Flood Lamp Gp (1). Mount flood lamp (1) to the top left and left corners of the radiator guard. Mount the left side floodlight with 285-5531 Bracket (8), four 8T-4121 Washers (6) and four 8T-4195 Bolts (5) .

Heated Mirrors (if equipped)

Illustration 111	g02377276
202-8649 Mirror As (Heated mirror) (1) 9X-6772 Cable Strap (2) 130-5301 Clip (3) 4D-8123 Clip (4) Two mounting bolts

1. Attach 4D-8123 Clip (3) to the top bracket for each mirror. Attach 130-5301 Clip (2) to the lower front bolt that mounts the bracket to the ROPS. Route the wiring harness for the mirror. Refer to Illustration 111. Use two 9X-6772 Cable Straps (1) in order to secure each harness to the bracket. Connect the harness to the wiring harness on the ROPS.

2. Secure mounting bolts (4) to 3.5 ± 0.5 N·m (2.58146 ± 0.375 lb ft).

Illustration 112	g02379096
(5) Heated mirror switch

Turn on the heated mirrors. Confirm that the mirrors are heated within 5 minutes.

Install Connectors on the Lift Cylinders

Illustration 113	g01509275

Install the following parts on the rod end of each lift cylinder: 4T-3797 Connector (3), 6J-5986 Retainer (2), 6J-5985 Pin (1) and 8T-8917 Bolts (4) .

Installation of the Push Arms to the Blade

Show/hide table



Illustration 114	g00390872

1. Raise the bulldozer blade to an upright position with an appropriate lifting device. Place appropriate stands under 9W-2939 Pins (1). The blade has a minimum weight of 10160 kg (22400 lb) and a maximum weight of 10750 kg (23700 lb).

Show/hide table



Illustration 115	g01510108
Installation of connector in left push arm

2. Use the following parts in order to install 122-4681 Connector (2) to left push arm: 9J-2364 Pin (3), 9J-2365 Retainer (4) and 7X-0379 Bolts (5). Tighten bolts (5) to a torque of 700 ± 90 N·m (515 ± 66 lb ft).

Show/hide table



Illustration 116	g01510171

3. Attach the left push arm assembly to the blade by attaching connector assembly (2). Use the following items to attach connector (2) : 9J-2364 Pin (3), 9J-2365 Retainer (4) and 7X-0379 Bolts (5). Tighten bolts (5) to a torque of 700 ± 90 N·m (515 ± 66 lb ft).

4. Repeat Steps 2 and 3 for the other push arm.

Show/hide table



Illustration 117	g01510214
Spacers on each side of cylinder rod

Show/hide table



Illustration 118	g01510233

Show/hide table



Illustration 119	g01510234

5. Install 308-2464 Tilt Cylinder Gp (8) to the right side of the blade with the following parts: 9J-2593 Pin (7), two 3G-5336 Spacers (6) that are located on each side of the cylinder rod, 9J-2365 Retainer (4) and two 7X-0379 Bolts (5) .

   Note: The grease fitting that is on the rod end must face downward.

6. Repeat step 5 for the 308-2462 Tilt Cylinder Gp on the left side of the machine.

Show/hide table



Illustration 120	g00392457
Typical example

7. Use an appropriate lifting device and an appropriate pry bar to align holes, as shown.

Show/hide table



Illustration 121	g01510253
Left push arm and tilt cylinder

8. Install the left tilt cylinder to the left push arm assembly by using the following parts: 9J-2366 Pin (9), 9J-2365 Retainer (4) and 7X-0379 Bolts (5). Tighten bolts (7) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

9. Repeat steps 7 and 8 on the other side of the machine.

Show/hide table



Illustration 122	g01510273
Stabilizer link

10. Install 153-0312 Link (10) on the blade with the following parts: 7T-4971 Bearing Cap (13), 7X-0418 Bolts (14), 2J-3507 Nuts (11) and 3G-9401 Shims (12). Shim the bearing cap. For additional information on the bearing cap, refer to ""Installation of the Push Arms and the Blade to the Machine" ". Follow Steps 14 through 16.

Show/hide table



Illustration 123	g01510474

11. Use the following parts to connect 3G-6623 Tube (16) to the right tilt cylinder: 4J-0520 O-Ring Seal (19), two 4L-6454 Bolts (17) and two 8T-2501 Bolts (18). Tighten bolts (17) and bolts (18) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

12. Attach tube (16) to the right tilt cylinder with the following parts: 8J-3146 Clamp (15) and two 5P-2228 Bolts (20). Tighten bolts (20) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).

Show/hide table



Illustration 124	g01510535

13. Use the following parts to connect 9W-5570 Tube (21) to the left tilt cylinder: 4J-0520 O-Ring Seal (19), two 4L-6454 Bolts (17) and two 8T-2501 Bolts (18). Tighten bolts (17) and bolts (18) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

14. Attach tube (21) to the left tilt cylinder with the following parts: 8J-3146 Clamp (15) and two 5P-2228 Bolts (20). Tighten bolts (20) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).

Show/hide table



Illustration 125	g01510555

15. Connect 143-7857 Hoses (23) to the tubes on the blade with the following parts: two 4J-5267 O-Ring Seals (27), four 1P-4576 Flanges (24), eight 8T-4896 Hard Washers (25) and eight 4L-9337 Bolts (26) .

16. Connect the other ends of the hoses to the left tilt cylinder with the following parts: two 4J-0520 O-Ring Seals (22), four 1P-4577 Flanges (28), eight 8T-4896 Hard Washers (25) and eight 9B-7237 Bolts (29) .

17. Repeat steps 15 and 16 for the hoses on the right side of the machine.

Show/hide table



Illustration 126	g01510614

18. Install 9W-5571 Guard (33) on the left tilt cylinder with the following parts: four 7X-0572 Hard Washers (30), two 7X-0380 Bolts (32) and two 7X-0383 Bolts (31). Tighten bolts (31) and bolts (32) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

19. Repeat Step 18 in order to install 3G-6251 Guard on the right tilt cylinder.

Show/hide table



Illustration 127	g01510619

20. Install four 143-7858 Hoses (36) to blocks (34) and (35) with the following parts: four 4J-5267 O-Ring Seals (27), eight 1P-4576 Flanges (24), sixteen 8T-4896 Hard Washers (25) and sixteen 9B-7237 Bolts (29) .

Installation of the Push Arms and the Blade to the Machine

Show/hide table



Illustration 128	g01510655
Typical example

1. Place a suitable stand or cribbing under each push arm (1) .

2. Slowly move the machine between push arms (1) until the push arms are engaged with trunnions (2) .

Show/hide table



Illustration 129	g01510679

3. Attach a hoist and a suitable lifting sling to bearing cap (3) .

4. Install bearing cap (3) and bolts (4) on push arm (1) without the shims. Tighten bolts (4) evenly and maintain an equal dimension on both sides of the bearing cap. The weight of the bearing cap is 39 kg (86 lb).

5. Insert an equal number of shims in the spaces between the bearing cap and the push arm. Then, add one additional shim to each of the spaces. The addition should allow the push arm to move freely on the trunnion within the specified clearance. The specified clearance between the trunnion and the push arm is 0.50 ± 0.25 mm (0.02 ± 0.01 inch).

6. Tighten bolts (4) to a torque of 1800 ± 200 N·m (1320 ± 150 lb ft).

7. Repeat Steps 3 through 6 for the push arm on the other side of the machine.

8. Release the pressure from the implement hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".

Show/hide table



Illustration 130	g01510688

9. Connect four hose assemblies (5) to the machine.

Show/hide table



Illustration 131	g01510694

10. Attach a hoist and a suitable lifting sling to stabilizer link (6) .

11. Raise the disconnected end of stabilizer link (6) to the front frame. The weight of the stabilizer link is 297.91 kg (656.77 lb).

Show/hide table



Illustration 132	g01511833

12. Start the engine. Carefully turn the front frame to the right until stabilizer link (6) is engaged with the front frame.

13. Stop the engine.

14. Install cap (7) and bolts (8) without the shims. Tighten bolts (8) evenly and maintain an equal dimension on both sides of the cap.

15. Insert an equal Number of shims in the spaces between the cap and the stabilizer link. Then, add one additional shim to each of the spaces. The addition should allow the stabilizer link to move freely on the trunnion within the specified clearance. The specified clearance between the trunnion and the stabilizer link is 0.50 ± 0.25 mm (0.02 ± 0.01 inch).

16. Tighten bolts (8) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).

Show/hide table



Illustration 133	g01511873

17. Start the engine. Extend the lift cylinder rods to the blade.

18. Stop the engine.

19. Install the following parts in both connectors that are located on the end of the lift cylinder rods: 9W-2939 Pin (10), 6J-5986 Retainer (9) and two 8T-8917 Bolts (11) .

Test Product Link

Product Link may need up to 15 minutes in order to establish communication with a satellite. Allow a minimum of 15 minutes to complete the following procedure.

In order to establish communication, the antenna for the Product Link module must have a clear view of the sky. Objects that obstruct the view of the antenna to the sky may result in a failure. If the antenna was obstructed during the test, retest the Product Link system with an unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees above the horizon. Check the following web site for satellite coverage in your area:

http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html

1. Connect Caterpillar Electronic Technician (ET) to the machine. The ET connector is located on the control panel on the right side of the cab.

2. Turn the engine start switch to the ON position.

3. Open the ET software program.

Show/hide table



Illustration 134	g01500919

4. ET will display a list of available electronic control modules. Select "Product Link". Press the "OK" button.

Show/hide table



Illustration 135	g01500920

5. Select "Diagnostic Tests" from the "Diagnostics" menu. Select "Wiggle Test".

Show/hide table



Illustration 136	g01459623

6. Read the warning that appears on the screen. Select the "OK" button.

Show/hide table



Illustration 137	g01459630

7. Select the "Groups" button near the bottom right corner of the screen.

Show/hide table



Illustration 138	g01459634

8. Choose the "New" button in order to create a new group for Product Link.

Show/hide table



Illustration 139	g01459640

9. Type "Product Link". Select the "OK" button.

Show/hide table



Illustration 140	g01459645
Available parameters and location of right arrow

10. In the left-hand column of available parameters, select "Number of GPS Satellites" under "Product Link". Then select the right arrow. In the left-hand column, select "Satellite Communications Status" under "Product Link". Select the right arrow.

11. Select the "OK" button.

Show/hide table



Illustration 141	g01459648

12. Select "Product Link". Press the "OK" button.

Show/hide table



Illustration 142	g01459655

13. In order to confirm the two types of communication with the satellite, the "Number of GPS Satellites" should be at least one. The "Satellite Communication Status" should be "Established". The screen in Illustration 78 shows that communication with GPS and the satellite is established.

    If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Established", the communication of Product Link is confirmed.

    If the "Number of GPS Satellites" is at least one and "Satellite Communication Status" is "Not Established", the wiggle test can be run in order to monitor status of the communication. Select the "Start" button in order to begin the wiggle test.

    Note: Leave ET running and do not navigate to a different screen in ET while the wiggle test is running. These actions will end the wiggle test. Allow the wiggle test to run for at least 15 minutes before failing Product Link.

    If a parameter changes during the wiggle test, the parameter will be highlighted in red. A 2 second beep will sound an alert. The parameter will remain red even if the parameter changes back to the original value.

    If communication is not established and the test has run for more than 15 minutes, check the antenna for damage. Also check the connection between the antenna and the radio. If the cable does not have a good connection, reconnect the cable. Repeat the test.

    If the connection between the antenna and the radio is good and no communication is established, refer to Troubleshooting, RENR7911, "Product Link 121/321".