Installation of the Variable Pitch, Angle, and Tilt Blade (S/N: R1W; R2W; R3W) on D6R XL, D6R XW, and D6R LGP Machines{6060} Caterpillar

Installation of the Variable Pitch, Angle, and Tilt Blade (S/N: R1W; R2W; R3W) on D6R XL, D6R XW, and D6R LGP Machines{6060}

Usage:

D6R III DLM

Track-Type Tractor:: D6R Series III XL (S/N: HKE1-UP; RFC1-UP); D6R Series III LGP (S/N: WCB1-UP; DLM1-UP); D6R Series III XW (S/N: HDC1-UP; MTJ1-UP)

Introduction

This Special Instruction provides the installation procedure for the Variable Pitch, Angle, and Tilt Blade on D6R LGP, D6R XW, and D6R XL machines.

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

Note: Do not perform any procedure in this Special Instruction until you read the information and you understand the information.

ReferenceService Manual, Parts Book, and 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.

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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

Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes.

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NOTICE

When a hoist is used to lift any part or assembly, stand clear of the area. Always make sure that the hoist has the correct capacity. Approximate weights of the components are shown in Table 1

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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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Do not coat any fasteners with oil or with grease prior to tightening. Instructions are given when lubrication is required.

Note: The variable pitch, angle, and tilt blade is installed on a D6R LGP, a D6R XW, or a D6R XL machine. The C-frame is already installed when the machine is delivered.

Approximate Weights

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Table 1
Weights for Specified Components of the Variable Pitch, Angle, and Tilt Bulldozer
Part Number	Description	Weight
223-3280	Blade and Edge Group	1635 kg (3600.0 lb)
227-8893	Tilt Cylinder	82 kg (180 lb)
261-0077	Angle Cylinder	64 kg (140 lb)

Necessary Parts

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Table 2
Variable Pitch, Angle, and Tilt Blades
Item	Part Number	Description	Qty
1A ⁽¹⁾	223-2350	Variable Pitch, Angle, and Tilt Blade	1
1B ⁽²⁾	223-3280	Variable Pitch, Angle, and Tilt Blade	1
1C ⁽³⁾	219-4260	Variable Pitch, Angle, and Tilt Blade	1

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^( 1 )	Use this component for D6R LGP machines.
^( 2 )	Use this component for D6R XW machines.
^( 3 )	Use this component for D6R XL machines.

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Table 3
Required Parts
Item	Part Number	Description	Qty
2	3B-8489	Grease Fitting	1
2a	9J-4782	Protector	1
3	089-8249	Spacer	2
4	104-4817	Pin	2
5	214-2295	Bearing Cap	2
6	223-3279	Retainer	2
7	245-1168	Pin	2
8	226-7191	Retainer	2
9	226-7192	Spacer	4
10	7X-0515	Hard Washer	2
11	7X-2577	Bolt (M24 × 3 × 90 mm)	8
12	8T-4123	Hard Washer	2
13	8T-4167	Hard Washer	8
14	8T-6430	Bolt (M20 × 2.5 × 50 mm)	2
15	8T-7338	Bolt (M16 × 2 × 45 mm)	2
16	214-2286	Shim	8
17	238-5040	Guard	1
18	238-6508	Hose Assembly	1
19	238-6509	Hose Assembly	1
20	148-8340	Connector Assembly	1
21	148-8346	Elbow Assembly	1
22	3G-8047	Grommet	2
23	3G-8054	Clip	2
24	3G-8057	Clip	2
26	8T-4133	Nut (M10)	2
27	8T-4139	Bolt (M12 × 1.75 × 30mm)	2
28	8T-4186	Bolt (M10 × 1.5 × 40 mm)	2
29	8T-4195	Bolt (M10 × 1.5 × 30 mm)	2
30	8T-4223	Hard Washer	2
31	225-3740	Link Group	1
32	227-8893	Tilt Cylinder	1
33	261-0077	Angle Cylinder	2
34	229-1516	Spacer	2
35	8T-4121	Hard Washer	6
36	279-6640	Pad	4

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Table 4
Parts of the 225-3740 Link Group
Item	Part Number	Description	Qty
43	-	Link Assembly	1
44	9J-4782	Protector	4
45	248-5048	Spacer	2
46	9X-8257	Washer	2
47	8T-4193	Bolt (M16 × 2 × 50 mm)	2

Machine Preparation

Procedure for Retracting Both Angle Cylinders

This procedure is only used if one of the angle cylinders is not fully retracted.

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Illustration 1	g01244747

Fully retract one angle cylinder (33) .

Attach a suitable lifting device the angle cylinder. Remove lines guard (F), shipment strap (E), bolts, and washers from that cylinder.

Secure cylinder to prevent movement.

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Illustration 2	g01244741

Disconnect and cap the hydraulic hoses (G) from the head end and the rod end of the cylinder.

Retract opposite cylinder.

Replace hoses, lines guard, shipment strap, bolts, and washers.

Preparation of the Blade and the Joint

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Illustration 3	g01165429

Attach the lube fitting (2) to the blade.

Thoroughly clean the surface of trunnion bearing (A). Remove any paint and debris from the surface of the trunnion bearing. Do not apply grease to the trunnion bearing at this time.

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Illustration 4	g01165146

Thoroughly clean the surface of trunnion ball (B). Remove any paint and debris. Do not apply grease to the trunnion ball.

Procedure for Connecting Both Angle Cylinders

This procedure is used on a machine the first time that the blade is attached to the machine. The machines are shipped from the factory with the lines to the angle cylinders disconnected.

Before connecting the hoses the pressure in the implements needs to be released. Turn the key to the ON position. Move the implement control lever to all of the positions to release any pressure.

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Illustration 5	g01244705

Attach a suitable lifting device the angle cylinder. Remove shipment strap (E) securing the right angle cylinder (33). Remove cover (F). Save Shipment strap (E) .

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Illustration 6	g01244706

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Illustration 7	g01244707

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Illustration 8	g01244708

Remove caps (37) from cylinder (33) and plugs (38) from the hoses. Connect the short hose to fitting (39) connect the long hose to fitting (40). Make sure that the long hose is on the inside of the short hose in area (H) .
Note: Some oil may drain from the hoses. Use a suitable container to catch the oil.

Install cover (F) .

Repeat Step 2 through Step 4 for the opposite side of the machine.

Procedure for the Tilt Cylinder and the Lines Group

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Illustration 9	g01244790

Attach a suitable lifting device the tilt cylinder. Use a pin (4) and two spacers (34) in order to attach the head end of tilt cylinder (32) to the frame. Install pin (4) from the top of the joint.

Use retainer (6), washer (12), and bolt (14) in order to secure the pin (4) .

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Illustration 10	g01244792

Install connector (20). Install elbow assembly (21) position the elbow assembly with the same orientation as shown in the Illustration.

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Illustration 11	g01244794

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Illustration 12	g01244796

Connect hose (19) to connector (20) that is located at the rod end of tilt cylinder (32). Refer to Illustration 11 for the orientation of the connector that is on the hose. Connect hose (18) to elbow assembly (21) that is located at the head end of tilt cylinder (32) .

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Illustration 13	g01244798
(C) Dimension 150 mm (6.0 inch)

Secure the hoses with clip (23) and clip (24) use two bolts (28), four washers (35), and two nuts (26) to attach grommet (22) .

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Illustration 14	g01244800
(L) Hose Length Approximately 540 mm (21.25 inch)

Secure the hoses with clip (23) and clip (24) use two bolts (29), and two washers (35) to attach grommet (22). The hose guarding is split to facilitate the installation of the clamp.

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Illustration 15	g01244801

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Illustration 16	g01244887

Remove the front tilt tube guard (41), bolts, and washers from the frame. Remove caps (42) from the tubes.

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Illustration 17	g01244802

Connect hose (19) from the rod end of the tilt cylinder to the outside tube assembly. Connect hose (18) from the head end of the tilt cylinder to the inside tube assembly.

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Illustration 18	g01244903

Replace the front tilt tube guard (41), the bolts, and the washers. Ensure that the hoses do not contact the front tilt tube guard in area (J) .

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Illustration 19	g01244803

Position guard (17) on tilt cylinder (32) and install two bolts (27) with washers (30) .

Procedure for Mounting the Blade Group on the Machine

Use an appropriate lifting device in order to raise blade (1) to an upright position. The blade must be in the upright position for this procedure. Refer to Table 1 for the approximate weights of the components.

Secure blade (1) with an appropriate support device. Use an appropriate lifting device or use blocks to stabilize blade (1) in the upright position.
Note: A block that is under the trunnion bearing must be six inches tall. The block should nearly contact the trunnion bearing to the blade weld.

Before the installation of the shims, preassemble the trunnion assembly without the shims. Use an appropriate lifting device in order to maneuver the blade.
Note: Do not apply a load to the blade with the machine while the blade is being supported by a hoist. Damage to the blade may result.

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Illustration 20	g01165147

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The blade can move or fall when the mounting pins are removed.

To prevent bodily injury, block the blade or support the blade with a hoist. Keep all personnel away from the blade.

Lift the blade with an appropriate lifting device. Move trunnion bearing (A) to trunnion ball (B) on the C-frame.

Mount trunnion bearing (A) onto trunnion ball (B) .

Install the upper split ring (5). Install four washers (13) and bolts (11) in split ring (5). Install the lower split ring (5). Install four washers (13) and bolts (11) in split ring (5). Full torque is not required at this time. When you are installing the split ring, ensure that there is an even gap (D) between each bearing cap (5) and bearing (A) .

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Illustration 21	g01165149

Measure dimension (D) between the surface of the trunnion bearing and the split ring.

Remove eight bolts (11) and eight washers (13). Remove both split rings (5) .

Use an appropriate lifting device in order to back off the blade so that the trunnion bearing is no longer mounted on the trunnion ball.

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Illustration 22	g01165148

Apply grease to the inside of trunnion bearing (A). Apply grease to both interior surfaces of two-piece split ring (5) .

Install shims (16). Add one shim more than dimension (D). (See Step 7 and Illustration 21.) Install the upper split ring (5) with four washers (13) and four bolts (11). Do not tighten at this time.

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Illustration 23	g01245589

Lift the blade with an appropriate lifting device. Move trunnion bearing (A) to trunnion ball (B) on the C-frame.
Note: If necessary, further loosen one bolt or more in order to maneuver the trunnion bearing onto the trunnion ball. Adjust the tightness of bolts (11), as needed. If necessary, remove the two outer bolts in order to facilitate the mounting of the trunnion bearing.

Mount trunnion bearing (A) onto trunnion ball (B) .

Install the lower split ring (5). Install shims. Install remaining washers (13) and bolts (11) in split ring (5). Tighten the bolts to a torque of 800 ± 100 N·m (590.0 ± 75.00 lb ft).

Test for proper shimming by manually moving the blade assembly. The blade should move without difficulty, binding, or play.

Grease fitting (2). After the fitting has been greased install protector (2a) on fitting (2) .

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Illustration 24	g01266503

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Illustration 25	g01266504
(Detail A1) View of fully extended pitch link (Detail A2) View of retracted pitch link

Remove the rod assembly (48) and the guard (49) from link group (31). Use spacers (45), washers (46), and bolts (47) in order to attach link assembly (43) to the frame and to the blade as shown in Illustration 24. There is a light press fit between the bearings and the pins. Attach the link so that the end with indicator pin (X) is attached to the C-frame.

Place blocks under the corners of the blade. Disconnect the hoist from the blade.

Lower the blade onto the blocks.

Set the length of the pitch link for job conditions.
The fully extended length of link assembly (43) is indicated with a pin-lock aligned with the groove in the rod handle. While facing the link as it would appear from the operator location, rotate the turn buckle (50) clockwise in order to shorten the link for fine grading or soft material conditions. The cutting edge angle will be approximately 52.5 degrees. Rotate the turn buckle (50) counterclockwise in order extend the link for tougher material conditions. The cutting edge angle will be approximately 56.5 degrees. Use the rod assembly to gage the pitch link setting. Do not use the rod as a lever to turn the turnbuckle. Use a large adjustable wrench to turn the turn buckle.

Grease the four grease fittings that are on the pitch link. After the fittings have been greased install protectors (44) on all four of the grease fittings.

Replace the rod assembly and the guard onto the link. Secure with pin-locks.

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Illustration 26	g01244940

Attach a suitable lifting device to the right angle cylinder (33). Position the right angle cylinder (33) on the blade.

Use pin (7), two spacers (9), and two pads (36) in order to attach the rod end of the right angle cylinder (33) to the blade. Install pin (7) from the top of the joint.

Use retainer (8), washer (10), and bolt (15) in order to secure pin (7) .

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Illustration 27	g01244942

Use an appropriate lifting device in order to position the tilt cylinder (32) on the blade.

Use pin (4) and two spacers (3) in order to attach the rod end of tilt cylinder (32) to the blade. Install pin (4) from the top of the joint.

Use retainer (6), washer (12), and bolt (14) in order to secure pin (4) .

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Illustration 28	g01244934

Attach a suitable lifting device to the left angle cylinder (33). Position the left angle cylinder (33) on the blade.

Use pin (7), two spacers (9), and two pads (36) in order to attach the rod end of left angle cylinder (33) to the blade. Install pin (7) from the bottom of the joint.

Use retainer (8), washer (10), and bolt (15) in order to secure pin (7) .

Check the oil level in the hydraulic tank. If necessary, fill the hydraulic tank. Start the engine. Cycle all of the cylinders to full stroke in both directions in order to purge air from the lines and from the cylinders. Stop the engine. Check the level in the hydraulic tank again. Refill the hydraulic tank to the FULL mark. Check for leaks.

Grease all of the grease fittings on the blade and on the cylinders. Use protectors (2a) on any fittings that do not already have one.

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

Standard Torque for Fasteners

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Table 5
Nuts and Bolts
Thread Size		Standard Torque ⁽¹⁾
Metric	Inch	Standard Torque ⁽¹⁾
M6		12 ± 3 N·m (9 ± 2 lb ft)
	1/4	12 ± 3 N·m (9 ± 2 lb ft)
	5/16	25 ± 6 N·m (18 ± 4 lb ft)
M8		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		2700 ± 300 N·m (2000 ± 220 lb ft)
	1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

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^( 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

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Table 6
Nuts and Bolts
Thread Size		High Torque
Metric	Inch	High Torque
M6		13 ± 3 N·m (10 ± 2 lb ft)
	1/4	13 ± 3 N·m (10 ± 2 lb ft)
	5/16	28 ± 7 N·m (21 ± 5 lb ft)
M8		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		175 ± 30 N·m (130 ± 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		530 ± 70 N·m (390 ± 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)