Installation of 6SU (S/N: D1Y; S6A) Bulldozer{5102, 6050, 6078} Caterpillar


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Installation of 6SU (S/N: D1Y; S6A) Bulldozer{5102, 6050, 6078} [REHS4383]
IMPLEMENTS
BULLDOZER GP
Installation of 6SU (S/N: D1Y; S6A) Bulldozer{5102, 6050, 6078}
1.1. Introduction
2.1. Safety
3.1. Approximate Weights
4.1. Procedure for Shimming
5.1. Installation of Mounting Group, Lift Cylinders, and Lift Cylinder Lines
6.2. Necessary Parts
7.2. Installation Procedure for Cylinder Mountings
8.2. Installation Procedure for Lift Cylinder and Lines
9.2. Shipping Instruction for Lift Cylinders
10.2. Installation of Trunnions
11.3. Necessary Parts
12.3. Installation Procedure
13.1. Assembly of Bulldozer
14.2. Necessary Parts
15.2. Assembly Procedure
16.1. Standard Torque for Fasteners
17.1. High Torque for Fasteners
Track-Type Tractor:
D6N (S/N: LJR1-UP; PER1-UP; MLW1-UP)

Introduction

The following special instruction provides the procedure for installation of the lift cylinders and the 6SU bulldozer with a single tilt cylinder.

Note: See the related section for the necessary parts list.

When the assembly is completed, prepare the machine for service. Refer to the Operation and Maintenance Manual.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

ReferenceService Manual, Parts Manual, Operation and Maintenance Manual.

Safety

------ WARNING! ------

Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

----------------------


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.


Note: Clean all pins and bores in order to remove any dirt or corrosion before assembly.

Note: Before, you begin this procedure attach a Do Not Operate Tag to the start switch of the machine.

Approximate Weights

Table 1
Cylinder Groups    
Item     Weight    
Lift Cylinder (1)     57 kg (125 lb)    
Tilt Cylinder    
92 kg (200 lb)    
( 1 ) The weight is for each lift cylinder.

Table 2
6SU Bulldozer    
Item     Weight    
Blade    
1030 kg (2270 lb)    
Arm Assembly (1)    
360 kg (795 lb)    
Support (2)    
139 kg (305 lb)    
Trunnion (3)    
41 kg (90 lb)    
( 1 ) The weight is for each arm assembly.
( 2 ) The weight is for each support.
( 3 ) The weight is for each trunnion.

Procedure for Shimming




Illustration 1g00494467

  1. Remove all of the shims from push arm (1) .

  1. Remove excess rust and paint from the contact surfaces of these components: the push arm, the cap and the shims.

  1. Install push arm (1) and cap (2) on trunnion (3) without shims. Use the largest torque from the following list in order to tighten the bolts.

    • Five percent of the specified torque

    • 50 N·m (37 lb ft)

    Maintain equal distance on both space (A) and space (B) of cap (2). Observe spaces (A) and (B) in order to determine the required number of shims.

  1. Loosen the bolts that are on cap (2). As needed, insert shims into spaces (A) and (B). When possible, use an equal number of shims for spaces (A) and (B) .

    Note: The number of shims at space (A) must be within one of the number of shims at space (B). For example, if space (A) has eight shims, space (B) must have seven, eight, or nine shims.

  1. Add one additional shim to space (A). Add one additional shim to space (B) .

  1. Tighten the bolts that are on cap (2) to the proper torque.

  1. The push arm should move freely on the trunnion. The specified minimum tolerance is 0.25 mm (0.010 inch).

    Note: It may be necessary to remove one or more shims after a short period of time. Wear can be caused by normal variations of the surface or variations in the thickness of the paint.

Installation of Mounting Group, Lift Cylinders, and Lift Cylinder Lines

Necessary Parts

Table 3
138-7033 Cylinder Mounting Gp    
Item     Part Number     Description     Qty    
1     8G-5501     Handrail (Right)     1    
2     3G-8891     Spacer     4    
3     115-4561     Bushing     2    
4     0S-0175     Clevis Pin     2    
5     6S-6646     Cotter Pin     2    
6     8G-5428     Pin     2    
7     4T-0231     Retainer     8    
8     8G-5502     Handrail (Left)     1    
9     115-4581     Support As (Left)     1    
10     115-4592     Link     2    
11     115-4591     Support As (Right)     1    
12     8T-4183     Bolt     2    
13     8T-4223     Hard Washer     12    
14     149-6309     Pin     6    
15     6V-7687     Locknut     2    
16     8T-4139     Bolt     12    
17     9W-9996     Bar     2    
18     4J-0805     Washer     34    

Table 4
271-8871 Lift Cylinder Lines Gp and 275-8416 Lift Cylinder Gp that are used with S/N:D1Y and ; S/N:S6A    
Item     Part Number     Description     Qty    
19     272-1387     Hose As     2    
20     272-1388     Hose As     2    
21     148-8341     Connector As     4    
22     5P-7464     Clip     4    
23     5P-7465     Clip     4    
24     5P-7468     Clip     2    
25     5P-7469     Clip     2    
26     6V-7359     Grommet     4    
27     7G-3833     Clip     2    
28     7G-3834     Clip     2    
29     8C-3174     Grommet     2    
30     8T-4121     Hard Washer     4    
31     8T-4136     Bolt     4    
32     8T-4139     Bolt     4    
33     8T-4244     Nut     4    
34     275-8416     Lift Cylinder Gp     2    

Installation Procedure for Cylinder Mountings




    Illustration 2g01907038

    Note: Coat all bearing surfaces of pins and bores at assembly with 5P-0960 Grease Cartridge .

  1. Install support assembly (11) on the machine by using the following parts: bushing (3), pin (6), retainer (7), bolt (16) and washer (13) .

  1. Install link assembly (10) to the machine and support assembly (11) by using two pins (14) and washer (18) .

    Note: Use washer (18) as shims.

    1. Install five shims (18) in order to locate the link assembly away from the centerline of the machine.

    1. Install three shims (18) on the machine side of the link assembly (10) inside the support assembly (11) .

    1. Install nine shims (18) to the opposite side of the link assembly (10) inside the support assembly (11) .

  1. Secure pins by using two retainers (7), two washers (13), and two bolts (16). Tighten bolts (16) to 105 ± 20 N·m (77 ± 15 lb ft).

  1. Install handle (8) to support (11) by using two washers (13) and two bolts (16). Tighten bolts (16) to 105 ± 20 N·m (77 ± 15 lb ft).

    Note: Use handle (8) on right side of the machine and handle (1) on the left side of the machine.

  1. Install bar (17) to support (11) by using pin (4) and pin (5) on the bottom and bolt (12) and locknut (15) on the top. Tighten bolt (12) to 105 ± 20 N·m (77 ± 15 lb ft).

    Note: Bar (17) must be free to rotate.

  1. Repeat Steps 1 through 5 for the other side of the machine.

Installation Procedure for Lift Cylinder and Lines

------ WARNING! ------

Personal injury or death can result if the lift cylinder is not secured when the lift cylinder is being attached to the blade or detached from the blade. The lift cylinders can rotate freely rearward when the cylinder rod is retracted.

Secure the lift cylinder until the cylinder rod is extended in order to prevent the lift cylinder from rotating rearward.

----------------------

    Note: Start on the right side of the machine.




    Illustration 3g01907043

    271-8871 Lift Cylinder Lines Gp

    (A) 475 ± 5 mm (18.7 ± 0.2 inch)

    Note: Grab handles on the radiator guard must be removed prior to the installation of the lift cylinders.

  1. Install the head end of lift cylinder (34) to support (11) by using pin (14), retainer (7), washer (13), and bolt (16). Torque for bolt (16) is 105 ± 20 N·m (77 ± 15 lb ft).

  1. Connect hose assembly (20) to the rod end of lift cylinder (34) with connector (21) .

  1. Secure hose assembly (20) to lift cylinder by using clips (22) and (23), grommet (26), bolt (31), and washer (30) .

  1. Connect hose assembly (19) to the head end of lift cylinder (34) with connector (21) .

  1. Install grommet (29), clips (27) and (28), bolts (35), and nuts (33) to hose assemblies (19) and (20) .



    Illustration 4g01908996

    Connections for use with 271-8871 Lift Cylinder Lines Gp

    (B) Head end

    (C) Rod end

  1. Connect the other end of hose assembly (20) to tee (C) .

  1. Connect the other end of hose assembly (19) to tee (B) .

  1. Install grommet (29), clips (27) and (28), bolts (35), and nuts (33) to link assembly (10) at dimension (A) .

  1. Repeat Steps 1 through 8 for the left side of the machine.

Shipping Instruction for Lift Cylinders

------ WARNING! ------

Personal injury or death can result if the lift cylinder is not secured when the lift cylinder is being attached to the blade or detached from the blade. The lift cylinders can rotate freely rearward when the cylinder rod is retracted.

Secure the lift cylinder until the cylinder rod is extended in order to prevent the lift cylinder from rotating rearward.

----------------------

  1. After, you disconnect lift cylinders (34) from the blade raise the cylinders to the UP position.

  1. Start on the right side of the machine and remove bottom bolt (12) and locknut (15) from bar (17) on support (11) .

  1. Using bolt (12) and locknut (15) connect bar (17) to the boss on lift cylinder (34) .

  1. Repeat Step 2 and Step 3 for the other side of the machine.

Installation of Trunnions

Necessary Parts

Table 5
319-7125 Bulldozer Trunnion Gp    
Item     Part Number     Description     Qty    
35     287-5751     Trunnion     2    
36     143-3148     Cover     2    
37     5P-1979     O-Ring Seal     2    
38     7X-2475     Bolt     20    
39     8T-4122     Hard Washer     20    
40     8T-4192     Bolt     4    
41     8T-4223     Hard Washer     4    

Installation Procedure




    Illustration 5g01907054

  1. Start on the right side and remove the existing cover from the track roller frame.

  1. Install cover (36) to the track roller frame by using seal (37), two washers (41), and two bolts (40). Torque bolts (40) to 120 ± 20 N·m (89 ± 15 lb ft).

  1. Install trunnion (35) to cover (36) by using ten washers (39), and ten bolts (38). Torque bolts (38) to 300 ± 40 N·m (220 ± 30 lb ft).

  1. Repeat Step 2 and Step 3 for the other side of the machine.

  1. Move the machine into position between the arm assemblies and turn the engine to the OFF position.

Assembly of Bulldozer

Necessary Parts

Table 6
320-5056 Push Arm Gp    
Item     Part Number     Description     Qty    
42     4F-0255     Pin     2    
43     4T-1520     Cage As     1    
44     115-4474     Arm As (Left)     1    
45     115-4473     Arm As (Right)     1    
46     8E-5701     Shim     52    
47     8E-5703     Shim     102    
48     8J-2880     Bearing Cap     4    
49     233-9134     Tilt Cylinder Gp     1    
50     124-9672     Tilt Brace Assembly     1    
51     160-6306     Bearing Cap     2    
52     3B-4626     Cotter Pin     2    
53     3F-6185     Pin     2    
54     6V-9167     Bolt     12    
55     7X-2566     Bolt     6    
56     8C-8478     Bolt     4    
57     8T-4123     Plated Washer     6    
58     8T-4131     Nut     22    
59     8T-5439     Washer     6    
60     8T-6381     Bolt     4    
61     6V-7742     Full Nut     4    

Table 7
115-4594 Semi-Universal Blade Gp    
Item     Part Number     Description     Qty    
62     115-4595     Semi-Universal Blade As     1    
63     9U-8079     Bit and Cutting Edge Gp     1    
64     3B-4630     Cotter Pin     2    
65     4T-1481     Link     1    
66     8H-8898     Pin     2    

Table 8
320-5928 Tilt Cylinder Lines Gp  (1)    
Item     Part Number     Description     Qty    
67     301-9621     Hose As     2    
68     6V-9169     Bulkhead Nut     2    
69     7T-6934     Hose As     1    
70     3Y-5405     Rubber     2    
71     4J-5267     O-Ring Seal     2    
72     8T-4223     Hard Washer     5    
74     8T-4139     Bolt     2    
75     8C-3205     Half Flange     4    
76     8T-4196     Bolt     8    
77     8T-4121     Hard Washer     8    
78     8T-4192     Bolt     3    
79     4T-3521     Guard     1    
80     289-4638     Guard As     1    
81     311-9054     Hose As     1    
82     6V-8398     O-Ring Seal     4    
83     6V-8981     Elbow     2    
85     198-4778     Hard Washer     2    
86     8T-4183     Bolt     2    
( 1 ) (S/N: MLW1-158; LJR1-133)

Table 9
346-1721 Tilt Cylinder Lines Gp  (1)    
Item     Part Number     Description     Qty    
84     346-1725     Hose As     1    
68     6V-9169     Bulkhead Nut     2    
69     7T-6934     Hose As     1    
70     3Y-5405     Rubber     2    
71     4J-5267     O-Ring Seal     2    
72     8T-4223     Hard Washer     5    
73     324-1724     Hose As     1    
74     8T-4139     Bolt     2    
75     8C-3205     Half Flange     4    
76     8T-4196     Bolt     8    
77     8T-4121     Hard Washer     8    
78     8T-4192     Bolt     3    
79     4T-3521     Guard     1    
80     289-4638     Guard As     1    
81     311-9054     Hose As     1    
82     6V-8398     O-Ring Seal     4    
83     6v-8981     Elbow     2    
85     198-4778     Hard Washer     2    
86     8T-4183     Bolt     2    
( 1 ) (S/N: MLW159-UP; LJR134-UP; PER1-UP)

Assembly Procedure

    Note: Remove all paint from mating surfaces.




    Illustration 6g01907376

  1. Support right push arm (45) and left push arm (44) with wood blocks.



    Illustration 7g01907377

    Note: Cage (43) must be installed to left push arm (44) with the bearing bore toward the left side.

  1. Use cage (43), six washers (57), six bolts (55), six nuts (58), and six washers (59) to assemble right push arm (45) and left push arm (44). Torque bolts (55) to 520 ± 70 N·m (383 ± 50 lb ft).



    Illustration 8g01907393

  1. Install arm assembly (A) to blade assembly (62) by using cap (48), four bolts (54), four nuts (58), and shims (47). Torque bolts (54) to 520 ± 70 N·m (383 ± 50 lb ft). For instructions on shimming, refer to ""Procedure for Shimming" ".

  1. Repeat Step 3 for the other side of the machine.



    Illustration 9g01907394

  1. Install link assembly (65) to blade (62) and arm assembly (A) by using two pins (66) and two cotter pins (64) .

    Note: Cotter pins (64) are installed on the right side only.




    Illustration 10g01907395

  1. Install brace assembly (50) to blade (62) with cap (48), shims (47), four bolts (56), and four nuts (58). Torque bolts (56) to 520 ± 70 N·m (383 ± 50 lb ft). For instructions on shimming, refer to ""Procedure for Shimming" ".



    Illustration 11g01907396

  1. Install the other end of brace assembly (50) to left push arm (44) by using pin (53), pin (42), and cotter pin (52) .



    Illustration 12g01907397

  1. Connect hose assemblies (69) and (81) to cylinder (49) by using seals (71), flanges (75), bolts (76), and washers (77) .



    Illustration 13g02117435

  1. Install guard assembly (80) to cylinder (49) by using two washers (72), two bolts (74), two washers (85), and two bolts (86) .



    Illustration 14g01907400

  1. Install cylinder (49) to bulldozer blade (62) with cap (48), shims (47), four bolts (54), and four nuts (61). For instructions on shimming, refer to ""Procedure for Shimming" ". Torque bolts (54) to 520 ± 70 N·m (383 ± 50 lb ft).



    Illustration 15g01907402

  1. Install cylinder (49) to right push arm (45) by using pin (53), pin (42), and cotter pin (52) .



    Illustration 16g01907414

  1. Measure the height from the ground to the center of trunnion assembly on the roller frame.

  1. Raise frame assembly (A) to the height that was measured in Step 12. Support frame assembly (A) with wood blocks.

  1. Move the machine between the push arms of frame assembly (A). Stop the engine.



    Illustration 17g01907415

  1. On each side, install cap (51) on frame assembly (A) with shims (46), two bolts (60), and two nuts (58). For instructions on shimming, refer to ""Procedure for Shimming" ". Torque bolts (60) to 520 ± 70 N·m (383 ± 50 lb ft).



    Illustration 18g01907486

  1. Install two elbows (83) and four seals (82) to bulldozer blade (62) with two nuts (68) .



    Illustration 19g02117255

    320-5928 Tilt Cylinder Lines Gp

    (S/N: MLW1-158; LJR1-133)

    (B) Head End

    (C) Rod End




    Illustration 20g02116633

    346-1721 Tilt Cylinder Lines Gp

    (S/N: MLW159-UP; LJR134-UP)

    (B) Head End

    (C) Rod End

  1. Connect hose (81) to the top elbow on the blade.

  1. Connect hose (69) to the bottom elbow on the blade.

  1. Connect hoses (67) to the elbows on the blade or connect hose (84) and hose (73) to the elbows on the blade.

  1. Install guard (79) and two pads (70) to hose assemblies and bulldozer blade (62) with three washers (72) and three bolts (78). Do not tighten bolts (78) .

  1. Connect the other end of hose assemblies (67) to the ports on the radiator housing or connect hose assembly (84) and hose assembly (73) to the ports on the radiator housing.

  1. Pull hose assemblies (67) to the left side of the machine in order to remove slack or pull hose assembly (84) and hose assembly (73) to the left side of the machine in order to remove slack.

    ------ WARNING! ------

    Personal injury or death can result if the lift cylinder is not secured when the lift cylinder is being attached to the blade or detached from the blade. The lift cylinders can rotate freely rearward when the cylinder rod is retracted.

    Secure the lift cylinder until the cylinder rod is extended in order to prevent the lift cylinder from rotating rearward.

    ----------------------



    Illustration 21g01907493

  1. Connect the lift cylinders to bulldozer blade (62) with a cap, shims, four bolts, and four nuts. For instructions on shimming, refer to ""Procedure for Shimming" ".

    Note: Items that are not numbered are part of the lift cylinder group.

  1. Check the oil in the hydraulic tank and fill the oil, if necessary. Cycle the cylinders to full stroke in both directions in order to purge air from the lines and the cylinders. Refill the hydraulic tank to the FULL mark.

  1. After assembly is complete, prepare the machine for operation. Refer to the Operation and Maintenance Manual for instructions.

Standard Torque for Fasteners

Table 10
Nuts and Bolts    
Thread Size     Standard Torque (1)    
Metric     Inch    
M6        
12 ± 3 N·m (106 ± 27 lb in)

12 ± 3 N·m (9 ± 2 lb ft)    
    1/4    
12 ± 3 N·m (106 ± 27 lb in)

12 ± 3 N·m (9 ± 2 lb ft)    
    5/16    
25 ± 6 N·m (221 ± 53 lb in)

25 ± 6 N·m (18 ± 4 lb ft)    
M8        
28 ± 7 N·m (248 ± 62 lb in)

28 ± 7 N·m (21 ± 5 lb ft)    
    3/8    
47 ± 9 N·m (35 ± 7 lb ft)    
M10        
55 ± 10 N·m (41 ± 7 lb ft)    
    7/16    
70 ± 15 N·m (50 ± 11 lb ft)    
M12        
100 ± 20 N·m (75 ± 15 lb ft)    
    1/2    
105 ± 20 N·m (75 ± 15 lb ft)    
M14        
160 ± 30 N·m (120 ± 22 lb ft)    
    9/16    
160 ± 30 N·m (120 ± 22 lb ft)    
    5/8    
215 ± 40 N·m (160 ± 30 lb ft)    
M16        
240 ± 40 N·m (175 ± 30 lb ft)    
    3/4    
370 ± 50 N·m (275 ± 37 lb ft)    
M20        
460 ± 60 N·m (340 ± 44 lb ft)    
    7/8    
620 ± 80 N·m (460 ± 60 lb ft)    
M24        
800 ± 100 N·m (590 ± 75 lb ft)    
    1    
900 ± 100 N·m (660 ± 75 lb ft)    
    1 1/8    
1300 ± 150 N·m (960 ± 110 lb ft)    
M30        
1600 ± 200 N·m (1180 ± 150 lb ft)    
    1 1/4    
1800 ± 200 N·m (1320 ± 150 lb ft)    
    1 3/8    
2400 ± 300 N·m (1780 ± 220 lb ft)    
M36        
2800 ± 350 N·m (2065 ± 260 lb ft)    
    1 1/2    
3100 ± 350 N·m (2280 ± 260 lb ft)    
( 1 ) Refer to Specifications, SENR3130, "Torque Specifications" or the topic "Torque Specifications" in the Operation and Maintenance Manual of your machine for additional information.

High Torque for Fasteners

Table 11
Nuts and Bolts    
Thread Size     High Torque    
Metric     Inch    
M6        
13 ± 3 N·m (115 ± 27 lb in)

13 ± 3 N·m (10 ± 2 lb ft)    
    1/4    
13 ± 3 N·m (115 ± 27 lb in)

13 ± 3 N·m (10 ± 2 lb ft)    
    5/16    
28 ± 7 N·m (248 ± 62 lb in)

28 ± 7 N·m (21 ± 5 lb ft)    
M8        
30 ± 7 N·m (266 ± 62 lb in)

30 ± 7 N·m (22 ± 5 lb ft)    
    3/8    
50 ± 10 N·m (37 ± 7 lb ft)    
M10        
60 ± 12 N·m (44 ± 9 lb ft)    
    7/16    
80 ± 15 N·m (77 ± 11 lb ft)    
M12        
105 ± 20 N·m (75 ± 15 lb ft)    
    1/2    
120 ± 20 N·m (89 ± 15 lb ft)    
M14        
170 ± 30 N·m (125 ± 22 lb ft)    
    9/16    
175 ± 30 N·m (130 ± 22 lb ft)    
    5/8    
240 ± 40 N·m (175 ± 30 lb ft)    
M16        
270 ± 40 N·m (200 ± 30 lb ft)    
    3/4    
430 ± 60 N·m (320 ± 44 lb ft)    
M20        
520 ± 70 N·m (383 ± 52 lb ft)    
    7/8    
700 ± 90 N·m (515 ± 66 lb ft)    
M24        
900 ± 100 N·m (665 ± 75 lb ft)    
    1    
1050 ± 150 N·m (775 ± 110 lb ft)    
    1 1/8    
1450 ± 150 N·m (1170 ± 110 lb ft)    
M30        
1800 ± 200 N·m (1320 ± 150 lb ft)    
    1 1/4    
2100 ± 250 N·m (1550 ± 185 lb ft)    
    1 3/8    
2700 ± 300 N·m (2000 ± 220 lb ft)    
M36        
3100 ± 350 N·m (2280 ± 260 lb ft)    
    1 1/2    
3600 ± 400 N·m (2650 ± 295 lb ft)