Installation of 9SU (S/N: 9RP; T9J) and 9U (S/N: 9MP; T9H) Bulldozer with a Single Tilt Cylinder {5104, 6050} Caterpillar

Track-Type Tractor

D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-4539)

Introduction

This Special Instruction provides the information that is necessary to install the lift cylinder. The instruction also includes the proper procedure for the installation of the 9SU and 9U Bulldozer with a single tilt cylinder.

Refer to the necessary parts lists in each section.

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

Do not perform any procedure that is outlined in this publication until you have read the information and you understand the information. Do not order any parts until you have read the information and you understand the information.

Reference: Service Manual,Parts Book, Operation and Maintenance Manual.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper 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: Do not coat any fasteners with grease or special lubricants prior to tightening. A light oil may be used. Instructions are given when lubrication is required.

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NOTICE
Maintain the oil in the hydraulic system at the correct level to prevent pump cavitation.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Approximate Weights

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NOTICE
When a hoist is used to lift any part or assembly, stand clear of the area. Always make sure the hoist has the correct capacity. Approximate weights of the components are shown in the chart which follows.

Table 1

Weights For The D9R Bulldozer
Part Number	Description	Weights
106-7365	Universal Blade Group	3869 kg (8530 lb)
102-6345	Semi-Universal Blade	4460 kg (9832 lb)
6E-4433	Bulldozer Lift Cylinder (Right)	180 kg (397 lb)
6E-4433	Bulldozer Lift Cylinder (Left)	180 kg (397 lb)
165-8633 (1)	Lift Cylinder Gp (Right)	180 kg (397 lb)
165-8633 (1)	Lift Cylinder Gp (Left)	180 kg (397 lb)
108-8283	Trunnion Assembly	101 kg (222 lb)
8E-6758	Connector Assembly	17 kg (37 lb)
8E-9445	Guard (Tilt Cylinder)	14 kg (31 lb)
6I-8087	Brace Assembly	112 kg (248 lb)
108-1028	Left Push Arm Assembly	699 kg (1540 lb)
109-6778	Tilt Cylinder Gp (Right)	257 kg (566 lb)
110-5744	Right Push Arm Assembly	699 kg (1540 lb)
110-5204	Stabilizer Link Group	86 kg (189 lb)
2461039	Stabilizer Link Gp	86 kg (189 lb)
110-5207	Guard	9 kg (20 lb)
115-2947	Guard Assembly	31 kg (68 lb)

(1)	This part is used on the D9R (S/N: ABK1-UP; ACL1-UP; WDM1-UP) only.

Shim Adjustment For The Push Arm Assembly

Illustration 1	g00566579

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

2. Install push arm (1) and cap (2) on trunnion (3) without shims. Use the largest torque from the following list 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). Insert the maximum amount of shims into spaces (A) and (B).

3. Remove the shims and loosen the bolts that are on cap (2). Add one additional shim to the stacks of shims for each side. Reinsert 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.

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

5. 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 vibrations of the surface or variations in the thickness of the paint.

Installation of Lift Cylinders

Necessary Parts

Table 2

104-3150 104-3152 Cylinder and Lines Group (Lift) 163-1268 163-1269 Cylinder and Lines Group (1)
Item	Part Number	Description	Qty
1	8E-1244	Bracket Assembly	2
2	8E-1248	Hose Assembly	2
2A	163-1619 (1)	Hose As	2
3	8E-1249	Hose Assembly	2
3A	163-1618 (1)	Hose As	2
4	4P-7581	Clip	2
5	4J-0520	Seal	8
6	6E-4433	Bulldozer Lift Cylinder	2
6A	165-8633 (1)	Lift Cylinder Gp	2
7	1P-4577	Flange	8
8	8T-4896	Washer	24
9	9B-7237	Bolt (3/8 by 1 1/4)	20

(1)	This part is used on the D9R (S/N: WDM1-UP) only.

Table 3

9J-7623 Lift Cylinder Mounting Group 246-1043 Cylinder Mounting Gp(1)
Item	Part Number	Description	Qty
10	8T-4170	Bolt (M20)	8
11	154-1580	Hard Washer	8
12	241-3853	Cap As	4
12A	233-4657	Yoke	2

(1)	This part is used on the D9R (S/N: WDM1-UP) only.

Table 4

104-3154 Lighting Group
Item	Part Number	Description	Qty
13	125-2001	Lamp Group	2
14	6V-1889	Clip	2
15	6S-4039	Grommet	2
16	6V-8801	Nut	2
17	5P-1075	Washer	18
18	8T-2502	Bolt (3/8 by 1 1/8)	16
19	9D-3768	Grommet	2
20	4D-7794	Clip	2
21	161-6601	Harness Assembly	2
22	9X-6772	Strap	6
23	8E-1476	Right-Hand Plate Assembly	1
24	8E-1477	Plate	1
25	115-5026	Left-Hand Plate Assembly	1
26	4P-7581	Clip	2

Table 5

125-2001 Lighting Group
Item	Part Number	Description	Qty
27	9W-4361	Mount	8
28	111-8314	Bracket Assembly	2
29	114-2368	Guard Assembly	2
30	147-0319	Lamp Group	2
31	5M-3062	Bolt (3/8 by 3/4)	2
32	5P-1075	Washer	18
33	5P-2955	Bolt (5/16 by 2 1/2)	2
34	6V-8189	Nut	2
35	6V-8801	Nut	16
36	8T-4224	Washer	4

Installation Procedure

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Illustration 2	g00566580

1. Tie the rod end of the cylinder to the base of the cylinder. This prevents the cylinder from extending during installation. Perform this procedure for both of the cylinders.

2. Remove the flanges and the covers on the ports at the top of each lift cylinder. Perform this procedure for both of the lift cylinders.
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   Illustration 3	g01118118

3. Install hose assemblies (2, 2A) and (3, 3A) to lift cylinder (6, 6A). Use two seals (5), four flanges (7), eight washers (8) and eight bolts (9). Perform this procedure for both of the lift cylinders. Tighten bolts (9) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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   Illustration 4	g01118133

4. Install clip (4) to lift cylinder (6, 6A). Hose assemblies (2, 2A) and (3, 3A) are marked for orientation.
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   Illustration 5	g00564596

5. Install bracket assembly (28) to lamp group (30) with bolt (33), two washers (36) and nut (34). Tighten bolt (33) to a torque of 25 ± 6 N·m (18 ± 4 lb ft) and nut (34) to a torque of 13 ± 3 N·m (10 ± 2 lb ft).
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   Illustration 6	g00566584

6. Install guard assembly (29) to left-hand plate assembly (25) with four mounts (27), eight nuts (35) and eight washers (32). Tighten nuts (35) to a torque of 20 ± 4 N·m (15 ± 3 lb ft).

7. Install lamp group (13) to guard assembly (29) with bolt (31) and washer (32). Tighten bolt (31) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

8. Connect the plug on harness assembly (21) into lamp group (13).

9. Install grommet (19) to left-hand plate assembly (25). Use strap (22) to secure harness assembly (21) to the guard assembly.
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   Illustration 7	g01118137

10. Use bolt (18), nut (16) and washer (17) to install clip (20) to cylinder group (6, 6A). Install clip (14). Tighten bolt (18) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 8	g01118143

11. Use four bolts (10), four washers (11), and two caps (12) to install cylinder groups (6, 6A) on the yoke (12A). Tighten bolts (10) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

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

12. Connect harness assembly (21) to the harness assembly that comes out of the radiator guard.

13. Install grommet (15). Install clip (26) to the radiator guard. Use straps (22) to secure harness assembly (21).

    Note: The leads that are capped to harness assembly (21) are for the optional dual lamp group.

14. Repeat Steps 1 through 13 for the other lift cylinder mounting group.
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    Illustration 9	g00566620

15. Connect hose assemblies (2) and (3) to the manifold on top of the radiator guard with four seals (5), flanges, washers, and bolts.

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

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    Illustration 10	g00566621

16. Reinstall the plate with three bolts and three washers. Tighten the bolts to a torque of 25 ± 6 N·m (18 ± 4 lb ft).
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    Illustration 11	g01118151

17. Remove the bolt that secures shipping bracket (1) on each lift cylinder (6, 6A) to the radiator guard.

    Note: Items that are not numbered are part of the lift cylinder mounting group. These items are included with the machine.

Installation of Push Arm Trunnions

Necessary Parts

Table 6

106-7364 Bulldozer Trunnion
Item	Part Number	Description	Qty
1	108-8283	Trunnion Assembly	2
2	7X-0404	Bolt (1 by 2 1/2)	28

Installation Procedure

Illustration 12	g00566623

1. Remove shipping cover (A) from the track roller frame.

   Note: All mating surfaces must be clean. All mating surfaces must be free of paint. If necessary, clean these surfaces.

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   Illustration 13	g00566624

2. Remove plug (B) and move plate (C) to the center of the machine as far as possible. Replace plug (B) in the plate and tighten to a torque of 50 ± 5 N·m (37 ± 4 lb ft). Adequate space for the installation of the trunnion should be available.

   Note: Check the oil reservoir for the pivot shaft for the correct oil level. Add oil, if necessary.

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   Illustration 14	g00566625

3. Install the guide pins (approximately 177.8 mm (7 inch) to 190.5 mm (7.5 inch) in length) into the track roller frame.

4. Start trunnion assembly (1) on the guide pins.
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   Illustration 15	g00566626

5. Install trunnion assembly (1) with 12 bolts (2). Tighten bolts (2) to a torque of 1050 ± 150 N·m (775 ± 111 lb ft) on both sides.

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

Assembly Of Bulldozer

Necessary Parts

Table 7

102-6345 Semi-Universal Blade and 106-7365 Universal Blade Group
Item	Part Number	Description	Qty
1	4T-7534	Pin	2
2	7X-2574	Bolt (M24 by 45)	8
3	6J-5179	Retainer	4
4	8E-6758	Connector Assembly	2
5	1U-2472	Pin	2

Table 8

8E-9890 Tilt Cylinder Lines Group
Item	Part Number	Description	Qty
6	8T-4196	Bolt (M10 by 35)	24
7	8T-4121	Washer	28
8	8T-4185	Bolt (M10 by 50)	4
9	110-5890	Tube Assembly	1
10	8C-3205	Flange	12
11	9W-9970	Hose Assembly	1
12	3G-7452	Hose Assembly	1
13	111-7746	Hose Assembly	1
14	8T-4136	Bolt (M10 by 25)	4
15	9X-2027	Washer	4
16	8E-9445	Right Guard Assembly	1
17	111-7745	Hose Assembly	1
18	115-2947	Guard Assembly	1
19	110-5205	Tube Assembly	2
20	4J-5267	Seal	9
21	110-5207	Guard Assembly	2
22	8T-4139	Bolt (M12 by 30)	16
23	5P-1076	Washer	16
24	7X-2573	Bolt (M24 by 40)	4
25	8T-4167	Washer	4
26	5H-2095	Clip	4

Table 9

8E-9889 Push Arm Group 246-1045 Stabilizer Push Arm Gp (1)
Item	Part Number	Description	Qty
27	110-5744	Push Arm (Right)	1
28	108-1028	Push Arm (Left)	1
29	110-5204	Stabilizer Link Group	1
29A	246-1039 (1)	Stabilizer Link Gp	1
30	109-6778	Tilt Cylinder (Right)	1
31	6I-8087	Brace Assembly	1
32	7X-2574	Bolt (M24 by 45)	8
33	6J-5179	Retainer	4
34	3G-7016	Pin	2
35	4T-7534	Pin	2

(1)	This part is used on the D9R (S/N: WDM1-UP) only.

Table 10

110-5204 Stabilizer Link Group 246-1039 Stabilizer Link Gp (1)
Item	Part Number	Description	Qty
36	7X-2578	Bolt (M24 by 200)	8
37	160-6307	Cap	2
38	8T-4001	Nut	8
39	110-5203	Link Assembly	1
39A	246-1040 (1)	Link	1
40	6I-8475	Shim	52

(1)	This part is used on the D9R (S/N: WDM1-UP) only.

Table 11

108-1028 110-5744 Push Arm
Item	Part Number	Description	Qty
41	109-5676	Right Push Arm Assembly	1
42	108-0685	Left Push Arm Assembly	1
43	116-8038	Cap	2
44	7X-2579	Bolt (M24 by 240)	8
45	8T-4001	Nut	8
46	3G-9401	Shim	52

Table 12

6E-4433 Lift Cylinder 165-8633 Lift Cylinder Gp (1)
Item	Part Number	Description	Qty
47	160-6310	Cap	2
48	8T-0672	Bolt (M24 by 160)	8
49	7X-0851	Nut	8
50	3G-0911	Shim	56

(1)	This part is used on the D9R (S/N: ABK1-UP; ACL1-UP; WDM1-UP) only.

Assembly Procedure

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Illustration 16	g00565016

1. Raise the blade to an upright position. Use appropriate supports. The blade must be in an upright position.

   Note: Clean out all bores on the blade.

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   Illustration 17	g00568442

2. Install connector assembly (4) to left push arm assembly (42). Use pin (35), retainer (33), and two bolts (32). Tighten bolts (32) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

   Note: Ensure that the vertical hole is to the rear of the horizontal hole and pin (35). Improper assembly may damage components. Refer to Illustration 17 for the proper orientation.

3. Repeat Step 2 for right push arm assembly (41).
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   Illustration 18	g00568441

4. Install left push arm assembly (42) with connector assembly to the blade. Use pin (1), retainer (3) and two bolts (2). Tighten bolts (2) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

5. Repeat Step 4 for right push arm assembly (41).
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   Illustration 19	g01118259

6. Install left brace assembly (31, 31A) to the blade. Use pin (5), retainer (3) and two bolts (2). Tighten bolts (2) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

7. Repeat Step 6 for right tilt cylinder group (30).

   Note: The tilt cylinder must be installed with the grease fitting on the rod end toward the ground.

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   Illustration 20	g01118266

8. Install left brace assembly (31, 31A) to left push arm assembly (42) with pin (34), retainer (33), and two bolts (32). Tighten bolts (32) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

   Note: Use an appropriate lifting device and appropriate pry bar to align the holes.

9. Repeat Step 8 for right tilt cylinder group (30).
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   Illustration 21	g00571815

10. Remove the shipping covers from right tilt cylinder (30). Install tube assembly (9) to the head end of the right tilt cylinder with seal (20), four washers (15), and four bolts (8). Tighten bolts (8) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).

11. Secure tube assembly (9) to right-hand tilt cylinder (30). Use bolt (22) and washer (23). Tighten bolt (22) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
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    Illustration 22	g01118290

12. Install stabilizer link group (29, 29A) to the blade. Use cap (37), four bolts (36), four nuts (38) and shims (40). Tighten bolts (36) to a torque of 900 ± 100 N·m (664 ± 74 lb ft). Refer to the topic “Shimming Procedure” in this Special Instruction for shimming instructions.

    Note: Make sure that the end of stabilizer link group (29, 29A) with six bosses for the lines guard is installed to the blade. The opposite end of stabilizer link group (29, 29A) has only two bosses.

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    Illustration 23	g01118291
    Stabilizer link group (A) 62.5 ± 5 mm (2.46 ± .20 inch) (B) 122.5 ± 5 mm (4.82 ± .20 inch)

13. Position tube assemblies (19) to dimension (A) of 62.5 mm (2.46 inch) and dimension (B) of 122.5 mm (4.82 inch) on stabilizer link group (29, 29A).

14. Clamp tube assemblies (19) to stabilizer link group (29, 29A) with four clips (26), three bolts (14), and three washers (7). Tighten bolts (14) to a torque of 60 ± 12 N·m (49 ± 9 lb ft).
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    Illustration 24	g00569679

15. Connect hose assemblies (11) and (12) to tube assemblies (19) with two seals (20), four flanges (10), eight washers (7) and eight bolts (6). Tighten bolts (6) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).

16. Connect the other end of hose assemblies (11) to the rod end of the tilt cylinder (30) and tube assembly (9) with two seals (20), four flanges (10), eight washers (7) and eight bolts (6). Tighten bolts (6) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
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    Illustration 25	g01118292

17. Connect hose assemblies (13) and (17) to the tube assemblies with two seals (20), four flanges (10), eight washers (7) and eight bolts (6). Tighten bolts (6) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
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    Illustration 26	g00569682

18. Install guard assembly (16) to the right tilt cylinder (30) with four washers (25) and four bolts (24). Tighten bolts (24) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
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    Illustration 27	g01118294

19. Install guard assemblies (21) to each end of stabilizer link group (29, 29A) with eight washers (23) and eight bolts (22). Install center guard assembly (18) to the stabilizer link group with four washers (23) and four bolts (22). Tighten bolts (22) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

Bulldozer Installation

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Illustration 28	g00569686

1. Block the push arms to the height of the trunnions.

2. Remove four nuts (45), four bolts (44), cap (43), and shims (46) from both push arms.

3. Move the machine into the push arms. Turn off the engine.
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   Illustration 29	g00568437

4. Install cap (43) to left push arm (28) with shims (46), four bolts (44) and four nuts (45). Tighten bolts (61) to a torque of 900 ± 100 N·m (664 ± 74 lb ft). Refer to the topic “Shimming Procedure” in this Special Instruction for shimming instructions.

5. Repeat Steps 1 through 4 for the other side of push arm (27).
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   Illustration 30	g00600076

6. Fasten left lift cylinder and right lift cylinder to the blade with caps (47), shims (50), four bolts (48) and four nuts (49). Tighten bolts (48) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
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   Illustration 31	g01118295

7. Install stabilizer link group (29, 29A) to the trunnion with cap (37), shims (40), four bolts (36), and four nuts (38). Refer to the topic “Shimming Procedure” in this Special Instruction for shimming instructions. Tighten bolts (36) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

   Note: Hose assemblies are installed on stabilizer link group (29, 29A) while the stabilizer link group is on the ground. Lift stabilizer link group (29, 29A) into position and install the hose assemblies to the proper ports on the radiator guard.

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   Illustration 32	g00569689

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   Illustration 33	g01118296
   Forward view from the operator station

8. Connect hose assemblies (13) and (17) to the hydraulic ports on the radiator guard. Use two seals (20), four flanges, eight washers, and eight bolts. Tighten the bolts to a torque of 60 ± 12 N·m (44 ± 9 lb ft).

   Note: Items that are not numbered are part of the lines group for the lift cylinders. These items are included with the machine.

9. Check the oil in the hydraulic tank. If necessary, fill the hydraulic tank. Cycle the cylinders by a full stroke. Cycle in both directions to purge air from lines and cylinders. Refill the hydraulic tank to the FULL mark.

10. After assembly is complete, prepare the machine for operation. Refer to the Operation and Maintenance Manual for proper machine preparation.