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

Wheel Dozer

854K (S/N: KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-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.

Table 1

Revision History
Revision	Summary of Changes
08	Added additional weld information to the Installation of the Beam and the Front Tires section.

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

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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.

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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 to prevent pump cavitation.

Clean all the surfaces before installing parts.

Reference: Refer to Parts Manual, SEBP5718 for S/N:H8M1-UP, Parts Manual, SEBP5774 for S/N:H9K1-UP, Parts Manual, M0070118 for S/N:KK31-UP, and Parts Manual, M0070116 for S/N:RM31-UP.Refer to Operation and Maintenance Manual, SEBU8653 and Service Manual, KENR5540 for (S/N: H9K1-UP; H8M1-UP). Refer to Operation and Maintenance Manual, M0074688 and Service Manual, UENR7607 for (S/N: KK31-UP; RM31-UP).

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	g02910518
854K Wheel Dozer

Components and Weights

Illustration 2	g02910536
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 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.
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   Illustration 4	g02717318

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

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

2. Clean the mounting surfaces on the front axle housing. Make sure that the machined surface is free of dirt.
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   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) to secure each side of the front axle housing to the front frame. Tighten all 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.
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   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) 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).
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   Illustration 10	g00268349

5. Use six 142-7074 Bolts (4) and use six 9M-2828 Hard Washers (3) 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).
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   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

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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).
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   Illustration 13	g01469267

2. Connect 312-3653 Tube As (3) to the port on the front of the axle.
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   Illustration 14	g02717329
   Left side of front axle (rear view) (4) 347-8702 Tube As (5) 6D-4246 Clip (6) 8T-8513 Clip (7) 5K-9660 Clip (8) 8R-8087 Spacer (9) 346-4438 Tube As (10) 7M-8798 Clip (11) 8T-6466 Bolt (12) 8T-4121 Hard Washer

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   Illustration 15	g02717325
   Inside front frame above front axle (4) 347-8702 Tube As (9) 346-4438 Tube As (13) 115-2516 Block (14) 115-2516 Block (15) 291-5620 Tube As (16) 264-8087 Tube As

3. Connect one end of 347-8702 Tube As (4) to the left side of 115-2516 Block (13). 347-8702 Tube As (4) is the left return line for the axle oil cooler.

4. Connect one end of 346-4438 Tube As (9) to 115-2516 Block (14). 346-4438 Tube As (9) is the left service brake line.

5. Connect the opposite end of 347-8702 Tube As (4) to the left brake housing. Connect the opposite end of 346-4438 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-6466 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 now.

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   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) 138-4409 Spacer (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) to secure the guard to the brake housing.

   Use 8T-6466 Bolt (20), 7X-7729 Washer (21), and 138-4409 Spacer (22) 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.

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   Illustration 17	g01469268
   Right side of front axle (rear view) (6) 8F-8513 Clip (10) 7M-8798 Clip (12) 8T-4121 Hard Washer (15) 347-8701 Tube As (16) 346-4439 Tube As (24) 6D-4244 Clip (25) 8T-4196 Bolt (26) 2S-4762 Clip

8. Install 346-4439 Tube As (16) and 347-8701 Tube As (15) on the right side of the front axle. 347-8702 Tube As is the right service brake line. 347-8701 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.
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   Illustration 18	g02717404
   Front axle (rear view)

10. Connect front wiring harness (27) to the wiring harness for the temperature sensor on the axle. Use three tie straps (28) to secure the harness to the axle housing.
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    Illustration 19	g01469908

11. Connect 317-5602 Hose As (29) to the port at the bottom of the differential.
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    Illustration 20	g01469910

12. Install 317-9193 Guard (30) on the axle housing. Use two 7X-0389 Bolts and two 242-0315 Spacers to install the plate.

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

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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).
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   Illustration 22	g02718678
   Front trunnion (top view) (3) 204-8000 Cable Tie Mounting (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer (6) 204-2281 Cable Strap

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   Illustration 23	g02718697
   (7) 286-7269 Bracket (8) 8T-4195 Bolt (9) 8T-4121 Hard Washer (10) 4V-1939 Clamp (11) 5V-6439 Plate (12) 7X-2534 Bolt (13) 9X-8256 Washer (14) 337-3359 Bracket As (15) 8T-4137 Bolt

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   Illustration 24	g02718740
   Rear axle (front view) (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer (8) 8T-4195 Bolt (16) 142-1657 Bracket As (17) 130-5300 Clip (18) 373-2449 Axle Temperature Wiring Gp

2. Connect 313-4443 Axle Harness (18) to temperature sensor (6).

   Note: Ensure that the harness is not stretched when the axle oscillates.

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   Illustration 25	g02717346
   Rear axle (front view) (19) 315-4138 Hose As (20) 115-2516 Block (21) 314-7943 Hose As (22) 115-2516 Block (23) 347-2308 Tube As (24) 346-0636 Hose As

3. Connect 314-7943 Hose As (21) to 115-2516 Block (22).

4. Connect 315-4138 Hose As (719) to 115-2516 Block (20).

5. Connect 347-2308 Tube As (23) to the top of the front trunnion support.

6. Connect 346-0636 Hose As (24) to the axle housing.
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   Illustration 26	g02717349
   Rear axle (rear view) (25) 347-2305 Tube As (26) 275-7769 Hose As

7. Connect 347-2305 Tube As (25) to the top of the rear trunnion.

8. Connect 275-7769 Hose As (26) to the top of the rear axle.

Installation of the Tires and Removal of the Truck Trailer

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Illustration 27	g01489274

1. Install two 138-8698 Rods into one of the wheels on the rear axle. The rods will be used to help guide the tire and rim onto the wheel.
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   Illustration 28	g00115530
   Typical example of installing a tire and rim

2. Use a hoist and use a sling 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 to hold the tire and rim assembly in place.
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   Illustration 29	g00115531
   Typical example

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

   Note: After installation of the rims/tires is completed, paint bolts and unpainted surfaces between the rim and final drive to prevent premature rust/corrosion.

4. Repeat Step 1 through Step 3 for the remaining rear tire.
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   Illustration 30	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.
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   Illustration 31	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.
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   Illustration 32	g02717320

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 to install the 153-7954 Beam.

2. Remove the shipping covers from the ends of the beam.
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   Illustration 33	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

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   Illustration 34	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 oversized. Do not trim the bottom or the back of the holes.

7. Slide the beam to the rear of holes (5) that is 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 to minimize embrittlement.

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    Illustration 35	g06423084
    View of bars and plates location

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    Illustration 36	g00400798
    Installation of the bars and plates

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    Illustration 37	g06423042
    (7A) 213-9870 Plate (7B) 213-9872 Plate (8A) 213-9859 Bar (8B) 213-9869 Bar (8C) 213-9865 Bar

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.

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    Illustration 38	g00402738
    Welding of the beam

13. Weld three fillet welds (10) to attach the beam to the square bar and the square bar to the frame. Completely weld all 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 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 to install both of the front tires on the machine.

Installation of the Trunnion and the Adapter Plate

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Illustration 39	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).
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   Illustration 40	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

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Illustration 41	g02723591

1. Attach an appropriate lifting device to the top of the cab. Lift the cab into position above the mounts.
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   Illustration 42	g02723592
   Right rear corner of cab

2. Route the machine wiring and air conditioner hoses into the right rear compartment on the cab.
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   Illustration 43	g02723595

3. Lower the cab onto the cab mounts.

4. Remove the panel below the rear window on the outside of the cab.
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   Illustration 44	g02723597

5. Use one 346-8408 Spacer, one 086-0299 Washer, and one 8T-4141 Bolt on each of the four mounts. Torque the bolts to 460 ± 60 N·m (340 ± 45 lb ft).
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   Illustration 45	g02723599

6. Install one 243-1175 Cover over each cab mount. Use four 8T-4138 Bolts to install each cover.
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   Illustration 46	g02717353
   Right rear compartment of cab

7. Attach the air conditioner hoses that are inside the right rear compartment on the cab. Attach 346-0991 Hose As (1) to the upper port on the air conditioner. Torque this connection to 54 ± 5 N·m (40 ± 4 lb ft). Connect the 342-9781 Hose As (2) to the lower port on the air conditioner. Torque this connection to 80 ± 5 N·m (60 ± 4 lb ft).
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   Illustration 47	g02717356
   Detail of hoses for the heater (bottom of cab, right side view) (3) 9X-2488 Hose Clamp (4) 5P-0767 Hose

8. Attach the hoses for the heater to the tubes that are in the right rear compartment of the cab.
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   Illustration 48	g02718930
   Right rear compartment of cab

9. Route the harness from the rear frame up through the bottom opening on the right side of the cab. Connect the machine harness from the rear frame in five places at the back of the cab.
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   Illustration 49	g02718932

10. Connect the camera and power cable for the cab. Use the hardware supplied on the connector to install the power cable for the cab.
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    Illustration 50	g02717363
    Underside of front of cab

11. Attach service brake control valve (6) to the bottom of the cab. Use four 8T-4133 Nuts and four 8T-4121 Hard Washers to attach the valve.
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    Illustration 51	g02723616
    Left side of machine under the cab

12. Attach the parking brake control cable to the linkage.
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    Illustration 52	g02723617
    Underside of left side of cab

13. Connect the steering neutralizer lines group to the manifold on the bottom of the cab. Refer to Illustration 50 for the hose routing.

Installation of the Steps and the Handrails

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Illustration 53	g02691039
(1) 375-7741 Handrail As (2) 375-7743 Handrail As (3) 8T-4139 Bolt (4) 7X-3392 Hard Washer (5) 355-9649 Step Gp (6) 8T-4194 Bolt (7) 5P-1076 Hard Washer

1. Install 375-7741 Handrail As (1) to the left rear bumper. Use two 8T-4139 Bolts (3) and two 7X-3392 Hard Washers (4).

2. Install 375-7743 Handrail As (2) to the left rear bumper. Use two 8T-4139 Bolts (3) and two 7X-3392 Hard Washers (4)

3. Install 355-9649 Step Gp (5) to the left rear bumper. Use four 8T-4194 Bolts (6), and four 5P-1076 Hard Washers (7).

4. Repeat Steps 1 through Step 3 to install the handrails and Step Gp for the right side of the machine. Use the same parts and hardware.
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   Illustration 54	g02868316
   (8) 362-0935 Handrail As (9) 8T-4139 Bolt (10) 7X-3392 Hard Washer

5. Install 362-0935 Handrail As (8) to the left rear bumper. Use four 8T-4139 Bolts (9), and four 7X-3392 Hard Washers (10).
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   Illustration 55	g02874566

6. On the same 362-0935 Handrail As at the back of the bumper: Secure the handrail As (8) using two 8T-4195 Bolts (9A), and two 7X-3392 Hard Washers (10).

7. Repeat Step 5 and Step 6 to install 362-0936 Handrail As to the right side of the machine. Use the same hardware.
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   Illustration 56	g02691356
   (11) 375-7739 Handrail As (12) 8T-4139 Bolt (13) 7X-3392 Hard Washer

8. Install 375-7739 Handrail As (11) to the left rear bumper. Use four 8T-4139 Bolts (12), and four 7X-3392 Hard Washers (13).

9. Repeat Step 8 to install 375-7739 Handrail As to the right side of the machine. Use the same hardware.
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   Illustration 57	g02691517
   (14) 365-0700 Handrail As (15) 8T-4139 Bolts (16) 7X-3392 Hard Washer

10. Install 365-0700 Handrail As (14) to the left stairway. Use eight 8T-4139 Bolts (15), and eight 7X-3392 Hard Washers (16).

11. Repeat Step 10 to install 365-0706 Handrail As to the right side of the machine. Use the same hardware.
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    Illustration 58	g02691619
    (17) 359-1109 Handhold As (18) 8T-4139 Bolt (19) 7X-3392 Hard Washer

12. Install 359-1109 Handhold As (17) to the inside left rear stairway. Use four 8T-4139 Bolts (18), and four 7X-3392 Hard Washers (19).

13. Repeat Step 12 to install 359-1114 Handhold As the right side of the machine. Use the same hardware.
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    Illustration 59	g02691659
    (20) 343-8725 Handrail As (21) 359-1103 Handrail As (22) 359-1104 Handhold As (23) 9X-2040 Screw

14. Assemble three handrails together. Assemble 343-8725 Handrail As (20), 359-1103 Handrail As (21), and 359-1104 Handhold As (22). Use eight 9X-2040 Screws (23).
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    Illustration 60	g02691936
    (24) 8T-4139 Bolt (25) 7X-3392 Hard Washer

15. Install the handrail to the left platform. Use eight 8T-4139 Bolts (24), and eight 7X-3392 Hard Washers (25).
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    Illustration 61	g02699659
    (26) 359-1104 Handhold As (27) 359-1103 Handrail As (28) 365-0744 Handrail As (29) 9X-2040 Screws

16. Assemble four handrails together for the right platform. Assemble 359-1104 Handhold As (26), two 359-1103 Handrail As (27), and 365-0744 Handrail As (28). Use 12 9X-2040 Screws (29).
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    Illustration 62	g02699677
    (30) 8T-4139 Bolts (31) 7X-3392 Hard Washer

17. Install the handrail assembly to the right platform. Use 16 8T-4139 Bolts (30), and 16 7X-3392 Hard Washers (31).
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    Illustration 63	g02691981
    (32) 365-3624 Handrail As (33) 8T-4139 Bolt (34) 7X-3392 Hard Washer

18. Install 365-3624 Handrail As (32) to the left platform. Use six 8T-4139 Bolts (33), and six 7X-3392 Hard Washers (34).

19. Repeat Step 18 using 366-1725 Handhold As. Use the same hardware.
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    Illustration 64	g02699802
    (49) 323-3746 Bracket (50) 323-3747 Bracket (51) 8T-4195 Bolt (52) 7X-7729 Washer (53) 127-0366 Spacer (54) 8T-6466 Bolt (55) 096-4883 Locknut

20. Install 343-8721 Gate As (48) to the left platform. Use the hardware listed above for the top and bottom hinge.
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    Illustration 65	g02699856
    (56) 351-8984 Bracket (57) 8T-4195 Bolt (58) 7X-7729 Washer (59) 248-0102 U-Bolt (60) 5C-7261 Nut (61) 8T-4224 Hard Washer (62) 300-4511 Latch As

21. Install the latch for the gate assembly. Use the hardware listed above to install the latch.
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    Illustration 66	g03490804
    (62) 300-4511 Latch As (K) 25 mm (0.98 inch)

22. Orient Latch As (62) for proper assembly and clearance. Refer to Illustration 66.
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    Illustration 67	g02699920
    (64) 365-0720 Guard Plate (65) 362-0940 Guard Plate (66) 346-6895 Guard Plate (67) 8T-4139 Bolt (68) 5P-1076 Hard Washer (69) 8T-4192 Bolt (70) 8T-3597 Weld Nut

23. Install the toe guards to the handrails on the left platform. Use the toe guards and hardware listed above.
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    Illustration 68	g02699976
    (71) 349-5616 Guard Plate (72) 346-6893 Guard Plate (73) 365-0719 Guard Plate (75) 8T-4139 Bolt (76) 5P-1076 Hard Washer

24. Install the toe guards to the handrails on the right platform. Use the toe guards and hardware listed above.

    71

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    Illustration 69	g02702717
    (77) 5P-7468 Clip (78) 5P-7469 Clip (79) 6V-1874 Grommet (80) 8T-4194 Bolt (81) 7X-3392 Hard Washer (82) 8T-4244 Nut

25. Secure the left-hand stairway handrail to handrail on the left platform. Use the hardware listed above.

26. Repeat the above step for the right side of the machine.

Installation of the Product Link (If Equipped)

Illustration 70	g02727716
(1) 263-9088 Communication Radio Gp (2) 290-2227 Plate As (3) 6V-8490 Bolt (4) 8T-4205 Hard Washer

1. Attach 263-9088 Communication Electronic Control Module (1) to the 290-2227 Plate As (2). Use four 6V-8490 Bolts and four 8T-4205 Hard Washers to connect the module to the plate.
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   Illustration 71	g02727717
   (1) Communication ECM (5) HID lamp (if equipped) (6) Flood lamp

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 to mount the plate to the canopy. Connect the ROPS wiring to the communication ECM.
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   Illustration 72	g03642730
   (7) 270-8544 Bracket As (8) 8T-4137 Bolt (9) 8T-4121 Hard Washer (10) 310-2391 Antenna As (11) 9X-6772 Cable Strap

3. Attach the 270-8544 Bracket As (7) to the right side of the ROPS canopy. Use two 8T-4137 Bolts and two 8T-4121 Hard Washers to attach the bracket.

4. Attach the 310-2391 Antenna As (10) to the 270-8544 Bracket As . Tighten the nut on the antenna to 5.0 ± 0.5 N·m (45 ± 4 lb in). Use one 9X-6772 Cable Strap (11) to strap the antenna cable to the link on the outside of the canopy. Use an extra cable strap to strap the cable to the link on the 270-8544 Bracket As.

5. Attach the antenna cable to the communication ECM. Use five 9X-6772 Cable Straps (11) to strap the cable to the underside of the ROPS canopy.

Radio Antenna - Install

Note: The following procedure applies only to machines that are equipped with a radio.

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Illustration 73	g02727725

1. Attach 9U-2334 Coaxial Cable Assembly (1) to the antenna connector on the left side of the bottom of the ROPS canopy.
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   Illustration 74	g02727727

2. Attach 9U-2332 Antenna As (2) to the antenna connector of the left side of the top of the ROPS canopy.
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   Illustration 75	g02727728

3. Attach 9U-2329 Coaxial Cable Assembly (3) to the antenna connector on the right side of the bottom of the ROPS canopy.
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   Illustration 76	g02727729

4. Attach 9U-2331 Antenna As (4) to the antenna connector on the right side of the top of the ROPS canopy.

Installation of the ROPS

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Illustration 77	g02717450

1. Remove 339-4691 Panel (1) from the right side of the platform and remove 339-4690 Panel (2) from the left side of the platform. To install the ROPS, the pictured cover assemblies are to be removed.
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   Illustration 78	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 is on the ROPS, when the ROPS is being installed.

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   Illustration 79	g02717459

3. Clean the ROPS mounting surface on the machine and on the ROPS.
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   Illustration 80	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.

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   Illustration 81	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.
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   Illustration 82	g02717471

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 83	g02864491

1. Place 314-9291 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 to remove the water.

2. Install 302-5176 Cover (2) onto the top rear of the ROPS.
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   Illustration 84	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) 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).
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   Illustration 85	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).
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   Illustration 86	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).
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   Illustration 87	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).
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   Illustration 88	g02864499

9. Place 314-9291 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 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).
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    Illustration 89	g02342943

11. Install 315-3460 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).
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    Illustration 90	g02342958

12. Attach two 126-7222 Angles (28) to each bracket assembly. Use one 8T-4136 Bolt with one 7X-7729 Washer 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).
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    Illustration 91	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 91.
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    Illustration 92	g02717489

15. 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.
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    Illustration 93	g02723793

16. Install two 333-1195 Precleaner As (47) onto the plenums.

Installation of Front Walkway

Illustration 94	g02717501

Illustration 95	g02717884
(1) 344-2064 Walkway As (2) 344-2063 Walkway As (3) 351-3319 Sheet (4) 8T-4956 Bolt (5) 5P-1076 Hard Washer (6) 8T-4244 Nut

1. Connect 344-2064 Walkway As (1), and 344-2063 Walkway As (2) to 351-3319 Sheet (3). Use eight 8T-4956 Bolts, 16 5P-1076 Hard Washers, and eight 8T-4244 Nuts.
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   Illustration 96	g02717897
   (7) 362-0951 Handrail As (8) 362-0949 Handrail As (9) 8T-4139 Bolt (10) 7X-3392 Hard Washer (11) 8T-3597 Weld Nut (12) 362-8234 Guard Plate (13) 362-8232 Guard Plate (14) 362-8233 Guard Plate (15) 8T-4192 Bolt (16) 5P-1076 Hard Washer (17) 8T-3597 Weld Nut

2. Install 2 362-0951 Handrail Assemblies (7), and one 362-0949 Handrail As (8) to the walkway assembly. Use 12 8T-4139 Bolts (9), 12 7X-3392 Hard Washers (10), and 12 8T-3597 Nuts (11).

3. Install 362-8234 Guard Plate (12) to 362-0951 Hand Rail (7). Install 362-8232 Guard Plate (13) to 362-0949 Hand Rail (8). Install 362-8233 Guard Plate (14) to 362-0951 Hand Rail (7). Use 12 8T-4192 Bolts (15), 12 5P-1076 Hard Washers (16), and 12 8T-3597 Nuts (17).
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   Illustration 97	g02717915

4. Install 306-3054 Tube (18) to the right side of the machine below the cab. Use four 8T-4184 Bolts (19), and four 8F-0492 Spacers (20).

5. Repeat the above Step for the left side of the machine. Use 306-3055 Tube.
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   Illustration 98	g02717919

6. Use a suitable lifting device and lower the walkway assembly onto the left and right tubes. Install the walkway to the tubes. Use eight 8T-4184 Bolts (19), and eight 8F-0492 Spacers (20).

7. Connect the back of the walkway on the left and right side to the left and right platforms.

HID Lights (If Equipped)

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Illustration 99	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.
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   Illustration 100	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).
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   Illustration 101	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 102	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 102. Use two 9X-6772 Cable Straps (1) 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 103	g02715227
(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 104	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

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Illustration 105	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).
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   Illustration 106	g01510108
   Installation of connector in left push arm

2. Use the following parts to install 122-4681 Connector (2) to 151-5219 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).
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   Illustration 107	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 151-5218 right push arm.
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   Illustration 108	g01510214
   Spacers on each side of cylinder rod

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   Illustration 109	g01510233

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   Illustration 110	g01510234

5. Install 367-2258 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 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 267-2259 Tilt Cylinder Gp on the left side of the machine.
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   Illustration 111	g00392457
   Typical example

7. Use an appropriate lifting device and an appropriate pry bar to align holes, as shown.
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   Illustration 112	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.
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   Illustration 113	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.
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    Illustration 114	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).
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    Illustration 115	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).
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    Illustration 116	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.
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    Illustration 117	g01510614

18. Install 347-2292 Guard As (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 to install 347-2293 Guard As on the right tilt cylinder.
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    Illustration 118	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), 16 8T-4896 Hard Washers (25), and 16 9B-7237 Bolts (29).

Installation of the Push Arms and the Blade to the Machine

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Illustration 119	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).
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   Illustration 120	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 extra 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".
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   Illustration 121	g01510688

9. Connect four hose assemblies (5) to the machine.
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   Illustration 122	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).
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    Illustration 123	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 extra 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).
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    Illustration 124	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 on the end of the lift cylinder rods: 9W-2939 Pin (10), 6J-5986 Retainer (9), and two 8T-8917 Bolts (11).

Commissioning Procedure

Make sure that all fluid levels are properly filled before the commissioning procedures begin.

Check the machine systems. Make sure that the systems are within specifications before the machine is put in service.

The list that follows shows the recommended assembly checks for the machine. The list also shows the recommended system checks for the machine. Perform the checks before the machine is delivered to the customer.

Update VIMS Configuration of the Machine

An update of the VIMS configuration is necessary when the machine is first delivered. After the machine is assembled, connect a computer to the service port and run Electronic Technician.

1. Select the "VIMS Main Module" ECM when prompted.

2. Go to the "Service" menu and select "ECM Date/Time".

3. Follow the instructions that are shown in Electronic Technician to update the clock on the VIMS ECM.

4. Go to the "Service" menu and select "Configuration".

5. Under the list of configurations for the "VIMS Main Module", select "General Information".

6. Under the list of parameters for "General Information", select "Equipment ID" and click the "Change" button.

7. Follow the instructions that are shown in Electronic Technician to assign the equipment number for the machine.

8. Close Electronic Technician and disconnect the computer from the machine.

Calibration

Calibrations should be performed on a surface that is smooth and level. Allow enough room for movement of the linkage.

In addition to the calibrations that are listed in this document, perform any calibration that has an "Active Calibration Required (FMI 13)" fault.

Implement Valve Solenoids

1. Press the "HOME" key on the Advisor module to bring up the "HOME" menu. Select "Service". Press the "OK" key.

2. Select "Calibrations" from the "Service" menu. Press the "OK" key.

3. Select "Implement" from the "Calibrations" menu. Press the "OK" key.

4. Select "Implement Valves" from the "Implement" menu. Press the "OK" key.

5. The Advisor module may ask for a password. Enter the password. Press the "OK" key to continue.

   Note: The default service mode password is "0". The service mode password can be changed using Electronic Technician.

6. Select "Blade Raise Sol" from the "Implement Valves" menu. Press the "OK" key to begin the calibration of the raise solenoid on the implement valve.

7. Follow the instructions that are shown on the Advisor display to perform the calibration.

   Repeat Step 1 through Step 6 to calibrate each of the implement valve solenoids. Select "Blade Lower Sol" to calibrate the lower valve solenoid. Select "Blade Tilt Left Sol" to calibrate the tilt left/tip back solenoid on the main control valve. Select "Blade Tilt Right Sol" to calibrate the tilt right/tip forward solenoid on the main control valve.

Activate Product Link

Refer to Special Instruction, REHS2365, "Installation Guide for Product Link PL121SR and PL321" for information on how to activate and configure satellite Product Link.

Refer to Special Instruction, REHS2368, "Installation Procedure for Product Link PL522/523 (Cellular)" for information on how to activate and configure cellular Product Link.