- Track-Type Tractor
- D5R2 (S/N: R5A1-UP)
Introduction
The following special instruction provides the procedure for installation of the lift cylinders and the 5SU bulldozer with a single tilt cylinder on a D5R Track-Type Tractor.
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.
Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.
Warnings
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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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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged. Failure to follow this instruction could lead to injury or death. Approximate weights of the components are shown in the table which follows. |
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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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Maintain the oil in the hydraulic system at the correct level to prevent pump cavitation. |
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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. |
Note: No oil or lubricant is recommended on new fasteners. When fasteners are reused, the fasteners should be cleaned before assembly. Also, lightly oil reused fasteners before reassembly. Instructions are given when lubrication is required.
Approximate Weights
| Lift Cylinder | |
|---|---|
| Description | Weight |
| Yoke(1) | |
| Lift Cylinder(2) | |
| (1) | The weight is for each yoke. |
| (2) | The weight is for each lift cylinder. |
| 5S Bulldozer and 5SU Bulldozer | |
|---|---|
| Description | Weight |
| 5SU Bulldozer Blade | |
| Push Arm (Right Side) | |
| Push Arm(Left Side) | |
| Tilt Cylinder | |
| Brace | |
| Trunnion(1) | |
| (1) | The weight is for each trunnion. |
Required Parts
| Required Parts for 5SU Bulldozer Installation | ||
|---|---|---|
| Qty | Part Number | Description |
| 23 | Full Nut | |
| 1 | Cutting Edge | |
| 23 | Bolt | |
| 23 | Hard Washer | |
| 1 | End Bit | |
| 1 | End Bit | |
| 2 | Cutting Edge | |
| 2 | Drive Screw | |
| 1 | Semi-Universal Blade As | |
| 1 | Identification Plate | |
| 1 | Link | |
| 2 | Cotter Pin | |
| 2 | Pin | |
| 1 | Guard As | |
| 4 | Hard Washer | |
| 7 | Bolt | |
| 2 | Cover | |
| 2 | Trunnion | |
| 20 | Hard Washer | |
| 20 | Bolt | |
| 6 | Bolt | |
| 2 | O-Ring Seal | |
| 1 | Cage As | |
| 52 | Shim | |
| 78 | Shim | |
| 3 | Bearing Cap | |
| 1 | Tilt Brace As | |
| 2 | Bearing Cap | |
| 1 | Tilt Cylinder Gp | |
| 1 | Arm As | |
| 1 | Arm As | |
| 4 | Square Nut | |
| 2 | Cotter Pin | |
| 2 | Pin | |
| 2 | Pin | |
| 8 | Bolt | |
| 6 | Bolt | |
| 4 | Bolt | |
| 4 | Bolt | |
| 6 | Washer | |
| 18 | Nut | |
| 4 | Hard Washer | |
| 6 | Hard Washer | |
| 2 | Rubber | |
| 1 | Guard | |
| 1 | Hose As | |
| 1 | Guard As | |
| 2 | Hose As | |
| 1 | Hose As | |
| 4 | O-Ring Seal | |
| 2 | Elbow | |
| 2 | Hard Washer | |
| 1 | Nut | |
| 2 | O-Ring Seal | |
| 2 | Nut | |
| 4 | Half Flange | |
| 2 | Clip | |
| 2 | Clip | |
| 10 | Hard Washer | |
| 2 | Bolt | |
| 9 | Bolt | |
| 5 | Hard Washer | |
Shipping Instruction for Lift Cylinders
Required Parts
| Shipping Parts for the Lift Cylinders | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 1 | Strap | 2 | |
| 2 | Two-Piece Clip | 2 | |
| 3 | Clip | 2 | |
| 4 | Hard Washer | 4 | |
| 5 | Hard Washer | 2 | |
| 6 | Bolt | 2 | |
| 7 | Bolt | 2 | |
| 8 | Nut | 2 | |
Installation Procedure
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| Illustration 1 | g03774078 |
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Hold-down location and components | |
Note: The following steps are for securing the lift cylinders when the rods on lift cylinders are not attached to the bulldozer. The hold-down is used only for shipping purposes.
Note: Store these parts in the toolbox or behind the seat after the bulldozer installation.
- Install clamp (2) and clamp (3) to the lift cylinder and strap (1) with bolt (7), two washers (4), and nut (8).
- Install the other end of strap (1) to the boss on the radiator guard with bolt (6) and washer (5).
Note: Use the middle hole in strap (1) to hold the lift cylinder to 75° from horizontal.
- Repeat Steps 1 and 2 for the other lift cylinder.
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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. |
Necessary Parts
| 426-3945 Bulldozer Trunnion | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 1 | Cover | 2 | |
| 2 | Trunnion | 2 | |
| 3 | Hard Washer | 20 | |
| 4 | Bolt | 20 | |
| 5 | Bolt | 4 | |
| 6 | O-Ring Seal | 2 | |
Installation Procedure
- Remove shipping cover (A) from the track roller frame.
Note: Remove paint from mating surfaces. Clean all the surfaces of the parts that will be installed.
Note: If the trunnions are removed, install the shipping covers before you operate the machine.
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Illustration 3 g00613710 - Install two guide studs in the track roller frame, as shown.
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Illustration 4 g03777024 - Install cover (1) onto the guide studs with seal (6). Install bolts (5), then tighten bolts (5) to a torque of
100 ± 20 N·m (74 ± 15 lb ft) .Show/hide table
Illustration 5 g03775200 - Position trunnion (2) on the guide studs. Install eight bolts of ten bolts (4) and washers (3), as shown. Remove the two guide studs.
- Install two remaining bolts (4) and washers (3). Tighten all bolts (4) to a torque of
270 ± 40 N·m (199 ± 30 lb ft) . - Repeat Steps 1 through 5 for the other side of the machine.
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| Illustration 2 | g00613704 |
Necessary Parts
| 444-2870 Push Arm Gp | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 1 | Cage As | 1 | |
| 2 | Shim | 52 | |
| 3 | Shim | 78 | |
| 4 | Bearing Cap | 3 | |
| 5 | Tilt Brace As | 1 | |
| 6 | Bearing Cap | 2 | |
| 7 | Tilt Cylinder Gp | 1 | |
| 8 | Arm As | 1 | |
| 9 | Arm As | 1 | |
| 10 | Square Nut | 4 | |
| 11 | Cotter Pin | 2 | |
| 12 | Pin | 2 | |
| 13 | Pin | 2 | |
| 14 | Bolt | 8 | |
| 15 | Bolt | 6 | |
| 16 | Bolt | 4 | |
| 17 | Bolt | 4 | |
| 18 | Washer | 6 | |
| 19 | Nut | 18 | |
| 20 | Hard Washer | 4 | |
| 21 | Hard Washer | 6 | |
| 396-4382 Bulldozer Installation Ar | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 22 | Link | 1 | |
| 23 | Cotter Pin | 2 | |
| 24 | Pin | 2 | |
| 453-0586 Tilt Cylinder Lines Gp | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 25 | Rubber | 2 | |
| 26 | Guard | 1 | |
| 27 | Hose As | 1 | |
| 28 | Guard As | 1 | |
| 29 | Hose As | 2 | |
| 30 | Hose As | 1 | |
| 31 | O-Ring Seal | 4 | |
| 32 | Elbow | 2 | |
| 33 | Hard Washer | 2 | |
| 34 | Nut | 1 | |
| 35 | O-Ring Seal | 2 | |
| 36 | Nut | 2 | |
| 37 | Half Flange | 4 | |
| 38 | Clip | 2 | |
| 39 | Clip | 2 | |
| 40 | Hard Washer | 10 | |
| 41 | Bolt | 2 | |
| 42 | Bolt | 2 | |
| 43 | Bolt | 3 | |
| 44 | Bolt | 9 | |
| 45 | Hard Washer | 5 | |
| 288-3925 Tilt Cylinder Guard Gp | |||
| Item | Part Number | Description | Qty |
| 46 | Guard As | 1 | |
| 47 | Hard Washer | 4 | |
| 48 | Bolt | 4 | |
Assembly Procedure
- Support right push arm (8) and left push arm (9) with wood blocks.
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Illustration 7 g03777797 Show/hide table
Illustration 8 g03777798 Note: Cage (1) must be installed to left push arm (9) with the bearing bore on the left side.
- Use cage (1), six washers (18), six bolts (15), six nuts (19), and six washers (21) to assemble right push arm (8) and left push arm (9). Tighten bolts (15) to a torque of
900 ± 100 N·m (665 ± 75 lb ft) .Show/hide table
Illustration 9 g03777799 - Use cap (4), shims (3), four bolts (14), and four nuts (19) to install push arm (A) to the bulldozer blade. For instructions on shimming, refer to "Procedure for Shimming". Tighten bolts (14) to a torque of
520 ± 70 N·m (385 ± 50 lb ft) . - Repeat Step 3 for the other side of the machine.
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Illustration 10 g03777801 - Use two pins (24) and two cotters (23) to install stabilizer link (22) to the bulldozer blade and to the push arm.
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Illustration 11 g03777802 - Use cap (4), shims (3), four bolts (17), and four nuts (19) to install brace (5) to the bulldozer blade. For instructions on shimming, refer to "Procedure for Shimming". Tighten bolts (17) to a torque of
520 ± 70 N·m (385 ± 50 lb ft) .Show/hide table
Illustration 12 g03777813 - Use pin (12), pin (13), and cotter (11) to install brace (5) to left push arm (9). (The center hole is the Neutral position.)
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Illustration 13 g03777818 - Use bolts (44), washers (40), seals (35), and flanges (37) to connect hoses (30) and (27) to tilt cylinder (7), as shown.
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Illustration 14 g03777820 - Use two washers (33),two bolts (42), two washers (45), and two bolts (41) to install guard (28) to the tilt cylinder.
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Illustration 15 g03778666 Show/hide table
Illustration 16 g00620260 - Use the cap, shims, four bolts, and four nuts to install tilt cylinder (7). For instructions on shimming, refer to "Procedure for Shimming". Tighten the bolts to a torque of
520 ± 70 N·m (385 ± 50 lb ft) .Show/hide table
Illustration 17 g03778685 - Use pin (12), pin (13), and cotter (11) to install tilt cylinder (7) to right push arm (8).
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Illustration 18 g03778691 - Use two nuts (36) to install two elbows (32) to the bulldozer blade. Install four O-ring seals (31) on elbows (32).
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Illustration 19 g03778699 - Connect hose (27) to the elbow on the bulldozer blade.
- Connect hose (30) to the elbow on the bulldozer blade.
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Illustration 20 g03778702 - Connect hoses (29) to elbows (32) on the bulldozer blade.
- Use four washers (45) and four bolts (43) to install guard (26) and two rubber pads (25) over the hoses on the bulldozer blade. Do not tighten bolts (43) yet.
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Illustration 21 g00620451 - Measure the distance from the ground to the center of the trunnion on the track roller frame.
- Raise both push arms (A) to the height that was measured in Step 17. Support both push arms (A) with wood blocks.
- Move the machine into position between push arms (A). Stop the engine.
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Illustration 22 g03778708 - On each side of the machine, use shims (2), two washers (20), two bolts (16), and two nuts (10) to install cap (6) on push arm (A). Position the nuts with the beveled edge against the casting of the push arm. For instructions on shimming, refer to "Procedure for Shimming". Tighten the bolts to a torque of
900 ± 100 N·m (660 ± 75 lb ft) .Show/hide tablePersonal 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 23 g00621558 Note: The items that are not numbered are shipped from the factory already installed.
- Use a cap, shims, four bolts, and four nuts to connect the lift cylinder to the bulldozer blade. For instructions on shimming, refer to "Procedure for Shimming". Tighten the nuts to a torque of
520 ± 70 N·m (385 ± 50 lb ft) . - Repeat Step 21 for the other side of the machine.
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Illustration 24 g03778709 - Connect the other ends of hoses (29) to the manifold on the radiator guard.
Note: Connect the hose from the head end of the tilt cylinder to center most port on the manifold.
- Pull hoses (29) to the left side of the machine in order to remove the slack.
Note: The items that are not numbered are part of the lift cylinder.
- Check the oil level in the hydraulic tank. If necessary, fill the hydraulic tank. Cycle the cylinders to full stroke in both directions in order to purge air from the lines and from the cylinders. Check the level in the hydraulic tank again. Refill the hydraulic tank to the FULL mark.
- After assembly is complete, prepare the machine for operation. Refer to the Operation and Maintenance Manual for instructions.
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| Illustration 6 | g03777727 |
Procedure for Shimming
- Remove all of the shims from the C-frame assembly.
- Remove excess rust and paint from the contact surfaces of the following components: the C-frame, the cap and the shims.
- Install the C-frame and the cap onto the trunnion without shims. Use the largest torque from the following list in order to tighten the bolts.
- 5 percent of the specified torque
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50 N·m (37 lb ft)
Maintain equal distance on both space (A) and space (B) between the cap and the C-frame arm. Observe spaces (A) and (B) in order to determine the required number of shims.
- 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.
- Add one additional shim to space (A). Add one additional shim to space (B).
- Tighten the bolts to the proper torque.
- The C-frame 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 time. Wear can be caused by normal vibrations of the surface or variations in the thickness of the paint.
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| Illustration 25 | g03732886 |
Lift Cylinder
- Remove all shims (F) from lift cylinder cap (G).
- Put cap (G) in place by hand with an equal number of shims (F) on each side of the joint.
- Rock cap (G) back and forth to determine the number of shims (F) required to keep the cap (G) from moving fore and aft on the trunnion.
- Add one more shim (F) per side and torque bolts (D) to the proper torque.
Note: The number of shims on one side of the cap must be within one of the number of shims on the other side. For example, if one side has eight shims, the other side must have seven, eight, or nine shims.
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Illustration 27 g02736792 - Use a pry bar to check that the cylinder rod rotates freely on the trunnion as shown in Illustration 27. The specified minimum clearance is
0.25 mm (0.010 inch) .Note: The removal of one or more shims may be necessary after a short time. Wear can be caused by normal vibrations of the surface or variations in the thickness of the paint.
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| Illustration 26 | g03741660 |
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(C) Nut
(D) Bolt (F) Shim (G) Cap | |
