Installation of 7S (S/N: RL7) and 7SU (S/N: RT7) on D7R Track-Type Tractor{6050, 6051, 6060, 6078} Caterpillar


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Installation of 7S (S/N: RL7) and 7SU (S/N: RT7) on D7R Track-Type Tractor{6050, 6051, 6060, 6078} [REHS8593]
WORK TOOLS
BLADE GP
Installation of 7S (S/N: RL7) and 7SU (S/N: RT7) on D7R Track-Type Tractor{6050, 6051, 6060, 6078}
1.1. Introduction
2.1. Safety
3.1. Weights
4.1. Procedure for Shimming
5.1. Installation of Lift Cylinders
6.2. Installation Procedure for Lift Cylinder and Lines
7.3. Necessary Parts
8.2. Installation Procedure for 373-9491 Cylinder Mounting
9.2. Installation Procedure for 373-9494 Lift Cylinder and Lines Gp , 373-9495 Lift Cylinder and Lines Gp , 373-9497 Lift Cylinder and Lines Gp , 373-9498 Lift Cylinder and Lines Gp
10.1. Shipping Instruction for Lift Cylinders
11.1. Installation of Trunnions
12.2. Necessary Parts
13.2. Installation Procedure
14.1. Assembly of Bulldozer with Single Tilt Cylinder
15.2. Necessary Parts
16.2. Assembly Procedure
17.1. Installation of Bulldozer Assembly
Track-Type Tractor:
D7R (S/N: R7B1-UP; R7C1-UP; R7H1-UP)

Introduction

This Special Instruction provides the procedure for the installation of the 7S and 7SU Bulldozers.

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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------


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.



NOTICE

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



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.


Note: No oil or lubricant is recommended on new fasteners. When fasteners are reused, the fasteners should be cleaned before assembly. Also, reused fasteners should be 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)     53 kg (117 lb)    
Lift Cylinder (each cylinder)    
135 kg (298 lb)    

Table 2
Weights for Specified Components of the Bulldozer Blade    
Description     Weight    
Blade (7SU)    
1850 kg (4084 lb)    
Blade (7S LGP)    
1980 kg (4371 lb)    
Push Arm (right)    
420 kg (930 lb)    
Push Arm (left)    
410 kg (910 lb)    
Stabilizer Link    
96 kg (210 lb)    
Brace    
88 kg (190 lb)    
Tilt Cylinder    
150 kg (330 lb)    
Trunnion (each trunnion)    
30 kg (66 lb)    

Procedure for Shimming




    Illustration 1g00292740

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

  1. Remove excess rust and paint from the contact surfaces of these components: the push arm, the cap and the shims.

  1. 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

    • 50 N·m (37 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.

  1. 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.

  1. Add one additional shim to space (A). Add one additional shim to space (B) .

  1. Torque the bolts on bearing cap (2) .

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

Table 4
373-9494 Lift Cylinder and Lines
373-9495 Lift Cylinder and Lines
373-9497 Lift Cylinder and Lines (LGP)
373-9498 Lift Cylinder and Lines (LGP)    
Item     Qty     Part Number     Description    
16     2     417-6243     Lift Cylinder (STD and XR)    
417-6244 Lift Cylinder (LGP)    
17     1     373-9501     Tube (right) (STD and XR)    
373-9504 Tube (right) (LGP)    
18     1     373-9502     Tube (left) (STD and XR)    
373-9503 Tube (left) (LGP)    
19     2     8E-8430     Hose (
1230 mm (48.4 inch) ) (STD and XR)    
139-5172 Hose (
1070 mm (42.1 inch)) (LGP)    
20     2     8E-8431     Hose (
950 mm (37.4 inch)) (STD and XR)    
139-5173 Hose (
890 mm (35 inch)) (LGP)    
21     4     1P-4577     Flange    
22     2     148-8391     Elbow (Group)    
23     2     153-6251     Connector    
24     6     4J-0520     O-Ring Seal    
25     2     373-9500     Plate    
26     4     8T-4186     Bolt    
27     12     5S-7379     Bolt    
28     12     5P-1075     Washer    
29     4     8T-4196     Bolt    
30     4     8T-4121     Washer    
31     2     8E-6269     Bracket    

Installation Procedure for 373-9491 Cylinder Mounting




    Illustration 2g00316447

  1. Use tie (A) to fasten the rod end. The tie prevents extension of the lift cylinder during the installation procedure.



    Illustration 3g00623548

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

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

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

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

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

Installation Procedure for 373-9494 Lift Cylinder and Lines Gp , 373-9495 Lift Cylinder and Lines Gp , 373-9497 Lift Cylinder and Lines Gp , 373-9498 Lift Cylinder and Lines Gp




    Illustration 4g00623548

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

  1. Pack two caps (4) with multipurpose type grease. Install the caps on the trunnions of lift cylinder (16) .

  1. Mount lift cylinder (16) and caps (4) on yoke (2) with four bolts (6). Tighten bolts (6) to a torque of 520 ± 70 N·m (383 ± 52 lb ft).

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



    Illustration 5g00829405

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

    Note: Make sure that O-ring seals are installed correctly before assembly of hydraulic lines and fittings.

  1. Install elbow (22) to lift cylinder (16) .

  1. Connect hose (19) to elbow (22) on lift cylinder (16) .

  1. Install connector (23) to lift cylinder (16) .

  1. Install tube (17) to connector (23) .

  1. Use these components to connect hose (20) to tube (17) : O-ring seal (24), two flanges (21), two washers (30) and two bolts (26) .

  1. Install bracket (31) to flanges (21) on tube (17) with two bolts (29) and with two washers (30) .

  1. Install plate (25) to lift cylinder (16) and bracket (31) with six bolts (27) and with six washers (28) .

  1. Use these components to connect the other ends of hoses (19) and (20) to quick-drop valve (C) on the radiator guard: two O-ring seals (24), four flanges, eight washers and eight bolts.

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

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

Shipping Instruction for Lift Cylinders




    Illustration 6g02839437

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

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

  1. Repeat Steps 1 and 2 for the other lift cylinder.

Installation of Trunnions

Necessary Parts

Table 5
251-9346 Bulldozer Trunnion    
Item     Qty     Part Number     Description    
1     2     250-1984     Trunnion    
2     32     8T-4122     Washer    
3     32     7X-0349     Bolt    

Installation Procedure




Illustration 7g00793321

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



    Illustration 8g00292304

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

  1. Remove O-ring plug (E) .

  1. 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) .

  1. 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) .




    Illustration 9g00292310

  1. 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).

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



    Illustration 10g00292311

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

  1. Torque the bolts.

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

Assembly of Bulldozer with Single Tilt Cylinder

Necessary Parts

Table 6
Straight Blade for LGP
Semi-Universal Blade    
Item     Qty     Part Number     Description    
1     1     462-1555     Blade and Edge (7S LGP)    
462-1549 Blade and Edge (7SU)    
462-1552 Blade and Edge (7SU with MCG Mount, ARO)
462-1550 Blade and Edge (7SU with Wear Plates, HD)
462-1553 Blade and Edge (7SU, Land Clearing)
462-1551 Blade and Edge (7SU, Landfill)
462-1557 Blade and Edge (7S LGP with MCG Mount, ARO)
462-1556 Blade and Edge (7S, Landfill)
2     2     8E-6754     Connector    
3     2     1U-0872     Pin    
4     4     8T-5460     Bolt    
5     2     6J-8570     Retainer    

Table 7
462-1581 Stabilizer Push Arm (Group)
462-1589 Stabilizer Push Arm (Group) for LGP    
Item     Qty     Part Number     Description    
6     1     462-1585     Stabilizer Link (Group) (STD and XR)    
462-1590 Stabilizer Link (Group) (LGP)    
7     1     462-1582     Push Arm (Left)    
1 462-1580     Push Arm (Right)    
8     1     6J-5342     Retainer    
9     2     1U-0872     Pin    
10     2     7X-0365     Bolt    
11     1     124-6274     Tilt Brace (Assembly)    
12     4     8T-4001     Nut    
13     26     3G-0911     Shim    
14     1     3G-0910     Cap    
15     4     8C-3290     Bolt    
16     1     4F-0255     Pin    
17     1     3F-4971     Pin    
18     1     3B-4627     Cotter    
19     1     3G-4533     Tilt Cylinder (Group)    
20     1     1U-0873     Pin    
21     2     6J-8570     Retainer    
22     4     8T-5460     Bolt    

Table 8
462-1588 Tilt Cylinder Lines  (1)
462-1592 Tilt Cylinder Lines  (2)
462-4421 Tilt Cylinder Lines  (1)
462-4422 Tilt Cylinder Lines  (1)    
Item     Qty     Part Number     Description    
23     1     1U-1235     Block    
24     2     1U-1344     Clamp    
25     1     4T-6443     Plate    
26     1     4T-6483     Guard As    
27     1     4T-6484     Guard    
28     2     9U-8544     Hose As    
29     1     462-7325     Guard As    
30     4     1P-4576     Half Flange    
31     1     4J-5140     O-Ring Seal    
32     4     4J-5267     O-Ring Seal    
33     2     5C-6565     Bolt    
34     2     5P-8112     Grommet    
35     1     7G-3832     Grommet    
36     1     7G-3833     Clip    
37     1     7G-3834     Clip    
38     4     7X-0274     Bolt    
39     5     8T-4123     Washer    
40     2     8T-4133     Nut    
41     2     8T-4137     Bolt    
42     2     8T-4195     Bolt    
43     4     8T-4224     Hard Washer    
44     2     8T-4779     Bolt    
45     8     8T-4896     Hard Washer    
46     4     8T-4994     Hard Washer    
47     5     8T-5460     Bolt    
48     4     8T-9398     Bolt    
49     8     9B-7237     Bolt    
50     2     9X-8257     Washer    
( 1 ) 7SU on Standard/XR
( 2 ) LGP
( 1 ) 7SU with Guard Lines
( 1 ) 7S LGP with Guard Lines

Table 9
463-1426 Tilt Cylinder Guard Gp    
Item     Qty     Part Number     Description    
51     1     4Y-8435     Guard    
52     4     8T-4223     Hard Washer    
53     4     8T-4192     Bolt    

Assembly Procedure




    Illustration 11g02856065

  1. Use a suitable lifting device to raise bulldozer blade (1). Connect the lifting device to the bulldozer blade at the lifting eyes on the top of the ends of the blade. Block the bulldozer blade in an upright position.



    Illustration 12g02856076

  1. Attach stabilizer link (6) to bulldozer blade (1). Use shims, one bearing cap, four nuts, and four bolts. In order to reduce friction, apply anti-seize compound to the bolts. Tighten the bolts to a torque of 520 ± 70 N·m (383 ± 52 lb ft).

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: The parts that are not numbered are part of stabilizer link (6) .




    Illustration 13g03712840

  1. Install one connector (2) to the end of push arm (7) with one pin (9), one retainer (21), and two bolts (22). Tighten bolts (22) to a torque of 520 ± 70 N·m (383 ± 52 lb ft).



    Illustration 14g00314404

    Push arm and connector assembly for the left side

  1. Install push arm (7) to bulldozer blade (1) with pin (3), retainer (5), and two bolts (4). Tighten the bolts to a torque of 520 ± 70 N·m (383 ± 52 lb ft).

  1. Repeat Steps 3 and 4 for the right side.



    Illustration 15g00298203

  1. Attach tilt brace (11) to the left side of bulldozer blade (1). Use shims (13), one bearing cap (14), four bolts (15), and four full nuts (12). Tighten the bolts to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.




    Illustration 16g00314463

  1. Attach the free end of tilt brace (11) to push arm (7). Use pin (17), pin (16), and cotter (18) in order to complete the attachment. Place one block (A) under push arm (7) in order to maintain the vertical position of bulldozer blade (1) .



    Illustration 17g02856096

  1. Attach tilt cylinder (19) to the right side of bulldozer blade (1). Use shims, one bearing cap, four nuts, and four bolts. Tighten the bolts to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: The parts that are not numbered are part of tilt cylinder (19) .




    Illustration 18g00314645

  1. Remove cover (C). Rotate tilt cylinder (19) in order to allow the hydraulic fluid to drain into a suitable container.



    Illustration 19g00314647

    View of the inner side of the push arm that is on the right side of the bulldozer

  1. Attach the free end of tilt cylinder (19) to the push arm (7). Use pin (20), retainer (8), and two bolts (10) in order to complete the attachment. Tighten bolts (10) to a torque of 520 ± 70 N·m (383 ± 52 lb ft).



    Illustration 20g03712971

  1. Install O-ring seal (31) in block (23) .

  1. Attach block (23) to tilt cylinder (19) with four washers (43) and four bolts (38) .



    Illustration 21g03712976

  1. Attach one hose (28) to the front location on tilt cylinder (19). Use O-ring seal (32), two flanges (30), four washers (45), and four bolts (49). Torque bolts (49) .

  1. Attach the other hose (28) to block (23). Use O-ring seal (32), two flanges (30), four washers (45), and four bolts (49) .



    Illustration 22g03714054

  1. Install two hoses (28) onto stabilizer link (6) using two clips (24), and two bolts (42) .



    Illustration 23g03712987

  1. Attach guard (27) to tilt cylinder (19) with four washers (46) and four bolts (48) .

  1. Attach plate (33) to tilt cylinder (19) with two bolts (25) .



    Illustration 24g03712989

  1. Install guard (51) using four bolts (53) and four washers (52) .



    Illustration 25g03714066

  1. Install guard (29) to stabilizer link (6) with two washers (39) and two bolts (47) .

  1. Install guard (26) using three washers (39), three bolts (47), two washers (50), and two bolts (44) .

Installation of Bulldozer Assembly

  1. Raise the ends of push arms (7) to the height of the trunnions on the machine. Use blocks (A) to achieve the desired height.

  1. Drive the machine toward the push arms until the trunnions contact the ends of the push arms.



    Illustration 26g00315343

  1. Install one bearing cap (I) on each push arm with shims (G), two bolts (H), and two nuts (F). Torque bolts (H) .

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: One bearing cap (I), 26 shims (G), two bolts (H), and two nuts (F) are included with each push arm (7) .




    Illustration 27g03714103

  1. Attach lift cylinder (J) to the right side of blade (1). Use shims, one bearing cap, four bolts, and four nuts.

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: Items that are not numbered are part of lift cylinder (J) .




    Illustration 28g02891961

  1. Attach stabilizer link (6) to the trunnion on the front of the machine with shims, one bearing cap, four bolts, and four nuts. In order to reduce friction, apply anti-seize compound under the bolt head and to the threads. Tighten the bolts to a torque of 520 ± 70 N·m (383 ± 52 lb ft).

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: Items that are not numbered are part of stabilizer link (6) .

  1. Attach lift cylinder (L) to the left side of blade (1). Use shims, one bearing cap, four bolts, and four nuts.

    Refer to ""Procedure for Shimming" " for the instructions on adding shims.

    Note: Items that are not numbered are part of lift cylinder (L) .




    Illustration 29g03712997

  1. Remove the shipping covers from manifold (M) .

  1. Connect each hose (28) to manifold (M) with one O-ring seal (32), two flanges, four washers, and four bolts. Torque the bolts.

    Note: The items that are not numbered are part of the manifold (M) .

  1. After the assembly has been completed, prepare the machine for operation. Refer to the machine's Operation and Maintenance Manual for instructions.

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