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

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

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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.

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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.

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 1	g00494467

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

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

3. 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.

4. 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.

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

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

7. 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

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Illustration 2	g01907038

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) .

2. 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.

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

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

3. 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).

4. 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.

5. 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.

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

Installation Procedure for Lift Cylinder and Lines

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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.

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Illustration 3	g01907043
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).

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

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

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

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

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Illustration 4	g01908996
Connections for use with 271-8871 Lift Cylinder Lines Gp (B) Head end (C) Rod end

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

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

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

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

Shipping Instruction for Lift Cylinders

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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.

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

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

4. 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

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Illustration 5	g01907054

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

2. 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).

3. 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).

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

5. 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.

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Illustration 6	g01907376

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

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Illustration 7	g01907377

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

2. 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).

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Illustration 8	g01907393

3. 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" ".

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

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Illustration 9	g01907394

5. 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.

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Illustration 10	g01907395

6. 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" ".

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Illustration 11	g01907396

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

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Illustration 12	g01907397

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

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Illustration 13	g02117435

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

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Illustration 14	g01907400

10. 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).

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Illustration 15	g01907402

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

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Illustration 16	g01907414

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

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

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

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Illustration 17	g01907415

15. 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).

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Illustration 18	g01907486

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

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Illustration 19	g02117255
320-5928 Tilt Cylinder Lines Gp (S/N: MLW1-158; LJR1-133) (B) Head End (C) Rod End

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Illustration 20	g02116633
346-1721 Tilt Cylinder Lines Gp (S/N: MLW159-UP; LJR134-UP) (B) Head End (C) Rod End

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

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

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

20. 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) .

21. 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.

22. 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.

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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.

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Illustration 21	g01907493

23. 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.

24. 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.

25. 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)