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.

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.

Approximate Weights

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

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

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

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.