Installation of the 7A (S/N: RA7) Bulldozer On D7R Track-Type Tractors{6050, 6052, 6060, 6701} Caterpillar

Track-Type Tractor:

D7R (S/N: R7B1-UP; R7C1-UP)

Introduction

This Special Instruction provides the procedure for the installation of the 7A Bulldozer.

Note: Each section contains the related parts list.

When you have completed this procedure, 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 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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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
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: No oil or lubricant is recommended on new fasteners. When fasteners are reused after being used in the field, the fasteners should be cleaned and lightly oiled before assembly. Instructions are given when lubrication is required.

Weights

Table 1

Weights for Specified Components of the Lift Cylinder
Description	Weight
Yoke (each yoke)	48 kg (105 lb)
Lift Cylinder (each cylinder)	150 kg (320 lb)

Table 2

Weights for Specified Components of the 7A Blade (Dual Tilt)
Description	Weight
Blade	1400 kg (3100 lb)
C-frame	1400 kg (3100 lb)
Push Arm (each push arm)	66 kg (145 lb)
Tilt Cylinder (each cylinder)	120 kg (270 lb)
Trunnion (each trunnion)	30 kg (65 lb)

Procedure for Shimming

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Illustration 1	g03773495

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 install bearing 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

   • 80 ± 10 N·m (60 ± 7 lb ft)

   Maintain equal distance on both space (A) and space (B) of bearing cap (2). Observe spaces (A) and (B) in order to determine the required number of shims.

4. Loosen the bolts that are on bearing 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 on bearing cap (2) to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft). See Illustration 19 and Step 16 in the ""Assembly Procedure" " below.

7. The push arm should move freely on the trunnion. The specified minimum tolerance is 0.25 mm (0.010 inch).

   Note: Removal of one or more shims may be necessary after a short time. Wear can be caused by normal vibrations of the surface. Wear can be caused by normal variations of the surface or variations in the thickness of the paint.

Installation of Lift Cylinders

Installation Procedure for Lift Cylinder and Lines

Necessary Parts

Table 3

373-9491 Cylinder Mounting Gp
Item	Part Number	Description	Qty
1	6V-0273	Seal	2
2	365-9398	Yoke	2
3	4T-4875	Pin	2
4	373-9493	Cap	4
5	3B-8489	Grease Fitting	2
6	7X-2568	Bolt	8
7	362-4551 (1)	Clamp	2
8	362-4552 (1)	Clamp	2
9	8T-8919 (1)	Bolt	2
10	8T-4223 (1)	Washer	4
11	9N-4233 (1)	Strap	2
12	6V-8188 (1)	Nut (1/2 inch by 13)	2
13	5M-3062 (1)	Bolt (3/8 inch by 16 by 3/4 inch)	2
14	8T-2561 (1)	Washer	2
15	7X-0521 (1)	Washer	2
15A	5P-0878	Seal	2

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Shipping Purposes Only

Table 4

373-9494 Cylinder and Lines 373-9495 Cylinder and Lines
Item	Part Number	Description	Qty
16	417-6243	Lift Cylinder	2
17	373-9501	Tube (right)	1
18	373-9502	Tube (left)	1
19	8E-8430	Hose (1230 mm for the right side)	1
20	8E-8430	Hose (1230 mm for the left side)	1
21	8E-8431	Hose (950 mm)	2
23	4J-0520	O-ring Seal	6
24	373-9500	Plate	2
25	8T-4196	Bolt (M10x1.5)	4
26	5S-7379	Bolt (3/8 inch by 16 by 7/8 inch)	12
27	5P-1075	Washer	12
28	8T-4186	Bolt (M10x1.5)	4
29	8T-4121	Washer	8
30	8E-6269	Bracket	2
31	1P-4577	Flange	4
32	148-8391	Elbow (1 7/16 inch by 12 to 1 5/8 inch by 12)	2
34	153-6251	Connector (1 3/16 inch by 12 to 1 11/16 inch by 12)	2

Installation Procedure for 373-9491 Cylinder Mounting Gp

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Illustration 2	g03745619

Note: Remove shipping covers and remove plugs from the radiator guard.

Note: Clean all surfaces of the parts that will be installed. Remove all paint from mating surfaces.

1. Lubricate seal (1) with multipurpose type grease. Install seal (1) into the radiator guard with the lip to the outside.

2. Pack the mounting bores in the radiator guard with multipurpose type grease.

3. Install yoke (2) into the radiator guard. Lock yoke (2) in place with pin (3). Install cover (A) and bolts (B) .

4. Install fitting (5) into the radiator guard. If grease is needed, add multipurpose type grease to the grease fitting.

5. Repeat Steps 1 through 4 for the other side of the machine.

Installation Procedure for 373-9494 Cylinder and Lines and for 373-9495 Cylinder and Lines

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Illustration 3	g03745681

Note: Clean all surfaces of the parts that will be installed. Remove paint from mating surfaces.

1. Install caps (4) on trunnions of lift cylinder (16) .

2. Mount lift cylinder (16) and caps (4) on yoke (2) with four bolts (6). Tighten bolts (6) to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

3. Repeat Steps 1 through 2 for the other side of the machine.

Note: Remove shipping covers from quick-drop valve (C) on the radiator guard. Remove shipping covers from lift cylinders (16) .

4. Install elbow (32) to lift cylinder (16) .

5. Connect hose (19) to elbow (32) .

6. Install connector (34) to lift cylinder (16) .

7. Install tube (17) to connector (34) .

8. Use these components to connect hose (21) to tube (17) : seal (23), two flanges (31), two washers (29) and two bolts (25) .

9. Install bracket (30) to flanges (31) on tube (17) with two bolts (28) and with two washers (29) .

10. Install plate (24) to lift cylinder (16) and bracket (30) with six bolts (26) and with six washers (27) .

11. Use these components to connect the other ends of hoses (20) and (21) to quick-drop valve (C) on the radiator guard: two seals (23), four flanges, eight washers and eight bolts.

    Note: The items that are not numbered are components of the quick-drop valve.

12. Repeat Steps 4 through 11 for the other side of the machine.

Shipping Instruction for Lift Cylinders

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Illustration 4	g03745756

1. install seal (15A) onto lift cylinder (16) .

2. Use these components to install clamps (7) and (8) to lift cylinder (16) : bolt (9), two washers (10), strap (11) and nut (12) .

3. Install the other end of strap (11) to the boss on the radiator guard with bolt (13) and washers (14) and (15) .

4. Repeat Steps 1 and 3 for the other lift cylinder.

Installation of Trunnions

Necessary Parts

Table 5

251-9346 Bulldozer Trunnion Gp
Item	Part Number	Description	Qty
1	250-1984	Trunnion	2
2	8T-4122	Washer	32
3	7X-0349	Bolt (5/8 inch by 11 by 3 inch)	32

Installation Procedure

Illustration 5	g03745835

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

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Illustration 6	g03745844

2. Place a suitable container below O-ring plug (E) in order to contain any fluid that drains.

3. Remove O-ring plug (E) .

4. Tap seal plate (C) in position against retainer plate (D) .

   Note: Step 4 eliminates the hydraulic pressure that forms between seal plate (C) and retainer plate (D). Also, this step allows adequate clearance between trunnion (1) and seal plate (C) .

5. Allow the fluid to drain. Properly collect and dispose of the fluid.

   Note: Make sure that the existing O-ring seal is correctly positioned on O-ring plug (E) .

   Note: Install O-ring plug (E) in seal plate (C) .

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Illustration 7	g03745873

6. Install guide pins (F) in the roller frame (B). The guide pins (F) should have a nominal size of 5/8 inch, 11 threads per inch, and a length that is within the range 178 to 191 mm (7.0 to 7.5 inch).

7. Slide the trunnion onto the guide pins (F) until the base of the trunnion is against the track roller frame.

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Illustration 8	g03745889

8. Install trunnion (1) with 16 bolts (3) and 16 washers (2).

9. Tighten bolts (3) to a torque of 215 ± 40 N·m (160 ± 30 lb ft).

10. Repeat Steps 1 through 9 for the other side of the machine.

Bulldozer Assembly Procedure With Dual Tilt

Necessary Parts

Table 6

462-1554 Angling Blade
Item	Part Number	Description	Qty
1	1U-1204	Trunnion	4
2	219-4481	Bolt (22x2.5)	16
2A	299-3439	Hard Washer	16
3	6Y-6752	Pin	1
4	313-2654	Retainer	1
5	8T-4779	Bolt (M16x2)	2
	462-1569	Blade As	1
	4B-4158	Drive Screw	2
	7T-6585	Bit and Cutting Edge Gp	1
	419-0093	Identification Plate	1

Table 7

462-1593 C-frame
Item	Part Number	Description	Qty
6	451-1256	Pin	1
7	9W-9009	C-frame	1
8	1U-0725	Retainer	1
9	7X-2562	Bolt (M20x2.5)	2
10	193-3063	Bearing Cap	2
11	9W-7602	Shim (0.8 mm)	52
12	3E-9850	Bolt (M30x3.5)	4
13	195-6283	Square Nut (M30x3.5)	4
13A	9X-8258	Washer	4

Table 8

462-1595 Bulldozer Brace
Item	Part Number	Description	Qty
14	4T-6211	Push Arm (Left)	1
	4T-6212	Push Arm (Right)	1
15	462-1596	Cap	2
16	3G-0911	Shim (0.8 mm)	54
17	7X-2454	Bolt (M24x3)	8
18	4T-8088	Screw	2
19	4T-5495	Ball Stud	2
20	160-6306	Cap	2
21	8E-5701	Shim (0.8 mm)	52
22	8T-6381	Bolt (M20x2.5)	4
23	251-8202	Nut (M20x2.5)	4
24	4F-1252	Pin	2
25	3J-1770	Lock Pin	2
26	9T-6113	Tilt Cylinder	2
27	1U-0873	Pin	2
28	6J-5342	Retainer	2
29	7X-0365	Bolt (3/4 inch by 10 by 1 1/2 inch)	4

Table 9

462-1597 Tilt Cylinder Lines Gp
Item	Part Number	Description	Qty
30	8E-6580	Tube (2380 mm)	1
31	8E-6581	Tube (1136 mm)	2
32	5S-8712	Block	4
33	8T-4186	Bolt (M10x1.5)	4
34	4T-6224	Hose (1950 mm)	2
35	4J-5267	O-ring Seal	10
36	1P-4576	Flange	4
37	8T-4896	Washer	8
38	9B-7237	Bolt (3/4 inch by 16 by 1 1/4 inch)	8
39	9W-8865	Hose (845 mm)	2
40	9W-8864	Hose (1190 mm)	2
41	4J-5140	O-ring Seal	2
42	1P-4574	Flange	4
43	8T-4224	Washer	8
44	6V-5782	Bolt (5/16 inch by 18 by 1 1/8 inch)	8
45	9W-8681	Bracket	2
46	8T-4994	Washer	6
47	8T-9398	Bolt (3/4 inch by 10 by 1 3/4 inch)	6
48	6V-1249	Grommet	2
49	5P-7465	Clip	2
50	5P-7464	Clip	2
51	8T-4139	Bolt (1/2 inch by 13 by 1 1/4 inch)	2
52	8T-4223	Washer	12
53	329-3356	Nut	2
54	9W-8682	Guard (Right)	1
55	5C-6565	Bolt (1/2 inch by 13 by 1 1/8 inch)	4
56	4T-6220	Guard (Left)	1
57	9W-0194	Guard	1
58	172-9966	Bolt (M12x1.75)	4
59	8C-3205	Flange	12
60	8T-4121	Washer	24
61	8T-4196	Bolt (10x1.5)	24

Assembly Procedure

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Illustration 9	g03772882

1. Raise the bulldozer blade. Block the bulldozer blade in an upright position.

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Illustration 10	g03772884

2. Use these components to install pivot pin (6) to the bulldozer blade: pin (3), retainer (4) and bolt (5). Tighten bolt (5) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).

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Illustration 11	g03772888

3. Use four blocks (32) and four bolts (33) to install tubes (30) and (31) to the blocks on the bulldozer blade. Center tube (30) on the bulldozer blade. Align the outer ends of tubes (31) with the ends of tube (30) on the bulldozer blade. Orient the center ports of tubes (31) toward the machine.

   Note: Make sure that you mark the hydraulic ports for the correct arrangement. Mark the top port (E) on the engine manifold. Mark the left port (E) on the blade. Mark the bottom port (F) on the engine manifold. Mark the right port (F) on the blade.

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Illustration 12	g03772905
The correct arrangement of one hose (34) is from the top port on the manifold to the left port on the blade. The correct arrangement of remaining hose (34) is from the bottom port on the manifold to the right port on the blade.

4. Use these components to connect hoses (34) to the tubes on the bulldozer blade: two O-ring seals (35), four flanges (36), eight washers (37) and eight bolts (38) .

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Illustration 13	g03772952

5. Use these components to connect hose (39) to the rod end of the tilt cylinder: O-ring seal (35), two flanges (36), four washers (37) and four bolts (38) .

6. Use these components to connect hose (40) to the head end of the tilt cylinder: O-ring seal (41), two flanges (42), four washers (43) and four bolts (44) .

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Illustration 14	g03772959

7. Install bracket (45) to the tilt cylinder with washer (46) and bolt (47) .

8. Install grommet (48) to hose (40). Use these components to assemble clips (49) and (50) to grommet (48) and to bracket (45) : bolt (51), two washers (both sides of bolt) (52) and nut (53) .

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Illustration 15	g03772970

9. Extend tilt cylinder (26) to approximately 1373 mm (54 inch) from the center of the head end to the center of the rod end.

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Illustration 16	g03772997

10. Use these components to install trunnion (1) to tilt cylinder (26) : the cap, the shims, four bolts and four nuts. Refer to ""Procedure for Shimming" " for instructions on the usage of shims. Tighten the bolts to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

    Note: The items that are not numbered are components of the tilt cylinder.

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Illustration 17	g03779123

11. Use these components to install guard (56) to the tilt cylinder: two bolts (47), two washers (46), two bolts (55) and two washers (52) .

12. Repeat Steps 5 through 11 for the other side of the machine. Use guard (54) for the tilt cylinder on the right side.

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Illustration 18	g03773244

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

14. Raise the rear center of C-frame (7). Block the C-frame to the height that was measured in Step 13.

15. Move the machine into position. The machine should be inside C-frame (7). Stop the engine.

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Illustration 19	g03773245

16. Use these components to install C-frame (7) to the trunnion: bearing cap (10), shims (11), two washers (13A), two bolts (12) and two nuts (13). Position the nuts with the beveled edge against the casting of the C-frame. Refer to ""Procedure for Shimming" " for instructions on the usage of shims. Tighten bolts (12) to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).

17. Remove the shipping brackets from the lift cylinders.

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Illustration 20	g03773249

18. Use these components to connect lift cylinder (B) to C-frame (7) : the cap, the shims, the four bolts and the four nuts. Refer to ""Procedure for Shimming" " for instructions on the usage of shims. Tighten the nuts to a torque of 370 ± 50 N·m (275 ± 35 lb ft).

    Note: The items that are not numbered are components of the lift cylinder.

19. Repeat Steps 17 and 18 for the other side of the machine.

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Illustration 21	g03773252

20. Align C-frame (7) with the bulldozer blade. Move the machine forward in order to insert the pivot pin through C-frame (7). Install retainer (8) with two bolts (9) to pivot pin (6). Tighten bolts (9) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

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Illustration 22	g03778686
(B) 1372 mm (54 inch) (C) 1676.8 ± 3.0 mm (66 ± 0.12 inch) (14) Push Arm (18) Screw (26) Tilt cylinder

21. Apply a heavy coat of multipurpose type grease to the threaded surfaces on screw (18) .

22. Adjust push arm (14) to dimension (C) with screw (18) .

    Note: The dimensions that are shown in Illustration 22 are without the caps or the shims. The measurement is from one face to the other face.

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Illustration 23	g03773290

23. Use these components to install trunnion (1) to push arm (14) : cap (15), shims (16) and four bolts (17). Refer to ""Procedure for Shimming" " for instructions on the usage of shims. Tighten bolts (17) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).

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Illustration 24	g03773298

24. Use these components to install ball stud (19) to push arm (14) : cap (20), shims (21), two bolts (22) and two square nuts (23). Position the nuts with the beveled edge against the casting of the push arm. Refer to ""Procedure for Shimming" " for instructions on the usage of shims. Tighten bolts (22) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

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Illustration 25	g03773302

25. Install push arm (14) to the bulldozer blade with four bolts (2). Tighten bolts (2) to a torque of 700 ± 90 N·m (515 ± 65 lb ft).

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Illustration 26	g03773304
Pin (25) is shown in this location for photographic purposes.

26. Install push arm (14) with ball stud (19) to the C-frame. Install pin (25) through the bottom of pin (24) after insertion of pin (24) through the ball stud.

27. Repeat Steps 25 and 26 for the other side of the machine.

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Illustration 27	g03773308

28. Install tilt cylinder (26) to the bulldozer blade with four bolts (2). Tighten bolts (2) to a torque of 700 ± 90 N·m (515 ± 65 lb ft).

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Illustration 28	g03773314

29. Use these components to install the other end of tilt cylinder (26) on push arm (14) : pin (27), retainer (28) and two bolts (29). Tighten bolts (29) to a torque of 370 ± 50 N·m (275 ± 35 lb ft).

30. Repeat Steps 28 through 29 for the other tilt cylinder.

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Illustration 29	g03773355

31. Use these components to connect hose (39) to tube (30) on the bulldozer blade: O-ring seal (35), two flanges (36), four washers (37) and four bolts (38) .

32. Use these components to connect hose (40) to tube (31) on the bulldozer blade: O-ring seal (35), two flanges (36), four washers (37) and four bolts (38) .

33. Repeat Steps 31 through 32 for the other side of the machine.

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Illustration 30	g03773364

34. Install guard (57) to the blocks on the bulldozer blade with washers (52) and bolts (58) .

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Illustration 31	g03773373
The correct arrangement of one hose (34) is from the top port on the manifold to the left port on the blade. The correct arrangement of remaining hose (34) is from the bottom port on the manifold to the right port on the blade.

35. Use these components to connect the other end of hoses (34) to the manifold on the radiator guard: two O-ring seals (35), four flanges (36), eight washers (37) and eight bolts (38) .

36. Check the oil in the hydraulic tank. Add oil, if necessary. Cycle the cylinders through several full strokes in both directions in order to purge air from the lines and from the cylinders. Refill the hydraulic tank to the full mark.

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Illustration 32	g03773493
(H) 25 to 45 mm (1.0 to 1.8 inch)

37. An improperly adjusted brace causes binding between the surface of pivot pin (6) and the surface of the bracket on the bulldozer blade. Check clearance (H) between pivot pin (6) and C-frame (7). If clearance (H) is not in the 25 to 45 mm (1.0 to 1.8 inch) range, then adjust the push arms (21) on both sides of the machine. See Illustration 32.

38. After you have completed this procedure, prepare the machine for operation. Refer to your machine 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 (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		2800 ± 350 N·m (2065 ± 260 lb ft)
	1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

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Refer to Specifications, SENR3130, "Torque Specifications" or the topic "Torque Specifications" in the Operation and Maintenance Manual of your machine for additional information.