Caterpillar Cat D7E LGP TRACK-TYPE TRACTOR (Prefix TJA) Service Repair Manual (TJA00001 and up).pdf

Shutdown SIS
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Product: TRACK-TYPE TRACTOR
Model: D7E LGP TRACK-TYPE TRACTOR TJA
Configuration: D7E TRACK-TYPE TRACTOR LGP TJA00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
D7E Track-Type Tractor Power Train
Media Number -KENR5606-03 Publication Date -01/12/2012 Date Updated -05/12/2012
i06007078
Recoil Cylinder - Disassemble
SMCS - 4151-015
Disassembly Procedure
Start By:
A. Remove the track adjuster and the recoil cylinder.
Table 1
Required Tools
Tool Part Number Part Description Qty
A 152-4252 Hydraulic Repair Bench 1
B
175-5507 Nitrogen Charging Group 1
338-0500 Regulator Assembly 1
346-3622 Relief Valve 1
C 8T-0372 Bolt 2
D
1H-3109 Leg 1
5F-9887 Adapter 1
5P-4807 Cap 1
- 1 1/2" Socket 1" Drive 1
E 9U-5919 Spanner 1
209-6756 Clamp As 1
4J-2620 Wear Ring 2
9X-3579 Wear Ring 2
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D7E TRACK-TYPE TRACTOR LGP TJA00001-UP (MACHINE) POWERED BY C...
2021/8/27
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

8T-7850 Wear Ring 2
F
FT-3233 Spanner Wrench As. 1
5P-3521 Pin 3
5P-3522 Pin 3
High pressure cylinder. Parts can separate with explosive force if
proper care is not used during disassembly.
This can cause injury or death.
Do not disassemble any part of this cylinder until you have read and
understand the instructions given in the service manual. Observe the
instructions given in the service manual.
Illustration 1 g03483240
1. Secure cylinder (1) to the hydraulic repair bench.
2. Remove bolts (2) and guard (3) .
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3. Attach Tooling (A) to valve (4) . Slowly vent the nitrogen from the cylinder, until all
pressure is released. Refer to Special Instruction, REHS5464, "Accumulator Discharging
and Charging Procedures" for further information.
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4. After all the pressure is released from the recoil cylinder, remove valve (4) from manifold
(5) .
5. Remove bolts (7) , bolts (8) , manifold (5) , and spring pin (6) .
Note: Cylinder groups that do not include spring pin (6) or holes for spring pin (6) Refer to
Special Instruction, REHS8537, "Installation Procedure for Installing Spring Pins in the
Recoil Cylinder of Certain D7E Track-Type Tractors".
6. Secure cylinder (1) to the hydraulic repair bench. Use Tooling (B) and the hydraulic repair
bench to remove head assembly (9) from cylinder (1) .
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Note: Some oil will drain during this step.
7. Remove O-ring seal (10) , O-ring seal (12) , and backup ring (11) from head assembly (9) .
8. Remove plug (13) from cylinder (1) .
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9. Reorient and secure cylinder (1) to the hydraulic repair bench.
10. Use Tooling (D) and the hydraulic repair bench to push the rod assembly until spacer (14)
can be removed.
Note: To prevent damage to cylinder (1) wrap Tooling (D) with padding (as shown).
11. Remove spacer (14) from the cylinder.
12. Remove O-ring seals (15) from spacer (14) .
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13. Remove rod assembly (16) and piston assembly (17) from cylinder (1) .
14. Inspect Cylinder (1) for any internal damage. Refer to Specifications, "Recoil Cylinder" for
more information.
15. Secure rod assembly (16) , piston assembly (17) , and Tooling (E) to the hydraulic repair
bench.
16. Remove spring pin (18) from between rod assembly (16) and piston assembly (17) .
Note: Cylinder groups that did not include a spring pin or setscrew (18) or had a spring pin
previously installed Refer to Special Instruction, REHS8537, "Installation Procedure for
Installing Spring Pins in the Recoil Cylinder of Certain D7E Track-Type Tractors".
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17. Use Tooling (F) and the hydraulic repair bench to remove piston assembly (17) while
holding the rod assembly with Tooling (E) .
18. Remove O-ring seal (19) and backup ring (20) from piston assembly (17) .
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19. Remove wear band (21) , energized wear ring assembly (22) , backup rings (23) , T seal
(24) , and wear band (25) from piston (17) .
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20. Use Tooling (F) and the hydraulic repair bench to remove cap assembly (26) from cylinder
(1) .
Note: Remove only if replacing cap assembly (26) . The seals can be replaced without
removing cap assembly (26) .
21. Remove scraper seal (27) , backup rings (29) , and O-ring seal (28) from cap assembly (26) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Aug 27 00:27:46 UTC+0800 2021
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D7E TRACK-TYPE TRACTOR LGP TJA00001-UP (MACHINE) POWERED BY...
2021/8/27

Shutdown SIS
Previous Screen
i06537125
Recoil Cylinder - Assemble
SMCS - 4151-016
Assembly Procedure
Table 1
Required Tools
A 152-4252 Hydraulic Repair Bench 1
B
175-5507 Nitrogen Charging Group 1
338-0500 Regulator Assembly 1
346-3622 Relief Valve 1
C 8T-0372 Bolt 2
D
1H-3109 Leg 1
5F-9887 Adapter 1
5P-4807 Cap 1
- 1 1/2" Socket 1" Drive 1
E
9U-5919 Spanner 1
209-6756 Clamp As 1
4J-2620 Wear Ring 2
9X-3579 Wear Ring 2
8T-7850 Wear Ring 2
F FT-3233 Spanner Wrench As. 1
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5P-3521 Pin 3
5P-3522 Pin 3
G FT-3144 Seal Installer 1
H 1U-9891 Hydraulic Oil Additive(1)
-
J FT-3234 Piston Sleeve 1
K - Loctite 243 -
(1)
Mix one part Additive with two parts clean 10wt Hydraulic Oil.
2/11
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1. Use Tooling (G) to install scraper seal (27) into cap assembly (26). Install O-ring seal (28)
and backup rings (29) into cap assembly (26).
2. Clean the threads of cap assembly (26). Lubricate O-ring seal (28) with Tooling (H).
3. Use Tooling (F) and the hydraulic repair bench to install cap assembly (26). Tighten cap
assembly (26) to a minimum torque of 300 N·m (220 lb ft).
4. Install O-ring seal (19) and backup ring (20) into piston assembly (17). Lubricate O-ring
seal with Tooling (H).
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5. Install wear band (21) and (22), backup rings (23), T seal (24), and wear band (25) onto
piston (17).
6. Secure rod assembly (16) and Tooling (E) to the hydraulic repair bench.
7. Install piston assembly (17) onto rod assembly (16). Tighten piston assembly (26) to a
minimum torque of 300 N·m (220 lb ft) until setscrew (18) can be installed.
Note: Cylinder groups that did not include a spring pin or setscrew (18) or had a spring pin
previously installed must Refer to Special Instruction, REHS8537, "Installation Procedure
for Installing Spring Pins in the Recoil Cylinder of Certain D7E Track-Type Tractors".
4/11
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8. Apply Tooling (K) to setscrew (18) and install. Torque to 20 ± 1 N·m (175 ± 8 lb in) . Stake
the internal threads at three equally spaced locations as shown in Illustration 7. Allow 1
hour of cure time before proceeding to Step 9 or handling the piston assembly.
9. Remove piston assembly (17) and rod assembly (16) from the hydraulic repair bench.
Remove Tooling (E) and Tooling (F).
10. Secure cylinder (1) to the hydraulic repair bench. Install Tooling (J) and lubricate with
Tooling (H).
5/11
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11. Install rod assembly (16) and piston assembly (17) into Tooling (J) and cylinder (1).
12. Use Tooling (D) and the hydraulic repair bench to push the head assembly and rod assembly
into cylinder (1).
Note: To prevent damage to cylinder (1) wrap Tooling (D) with padding (as shown).
13. Install O-ring seals (15) onto spacer (14).
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14. Lubricate O-ring seals (15) with Tooling (H) and install spacer (14) into the cylinder.
15. Install O-ring seal (12), and backup ring (11) into head assembly (9). Lubricate O-ring seal
(11) with Tooling (H).
16. Use Tooling (B) and the hydraulic repair bench to install head assembly (9) into cylinder
(1). Tighten head assembly (9) to a minimum torque of 300 N·m (220 lb ft).
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17. Install O-ring seal (10) onto head (9).
18. Add 236.8 mL (8.0 oz) of Tooling (H) through the center hole in head (9) into the cylinder.
8/11
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19. Install manifold (5), bolts (7), bolts (8), and spring pin (6).
Note: Cylinder groups that do not include spring pin (6) or holes for spring pin (6) Refer to
Special Instruction, REHS8537, "Installation Procedure for Installing Spring Pins in the
Recoil Cylinder of Certain D7E Track-Type Tractors".
Note: Align manifold (5) with nitrogen port pointing toward the plug side of cylinder (1),
shown in Illustration 7.
20. Install valve (4) into manifold (5).
Dry nitrogen is the only gas approved for use in the accumulator.
Charging the accumulator with oxygen gas will cause an explosion. This
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danger will not happen if nitrogen cylinders with standard CGA
(Compressed Gas Association, Inc.) Number 580 connections are used.
When you order nitrogen gas, be sure that the cylinders are equipped
with CGA No. 580 Connections. Do not use color codes or other
methods of identification to tell the difference between nitrogen and
oxygen cylinders.
21. Attach Tooling (A) to valve (4). Charge the recoil cylinder with dry nitrogen at 21° C
(70° F) to 17719 ± 344 kPa (2570 ± 50 psi). Refer to Testing and Adjusting, "Accumulator
(Track Tension) - Test and Charge" for more information.
22. Install guard (3) and bolts (2) .
23. Install plug (13) into cylinder (1).
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End By:
a. Install the recoil cylinder and the track adjuster.
Fri Aug 27 00:28:42 UTC+0800 2021
11/11
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Shutdown SIS
Previous Screen
i05801465
Track Roller Frame - Remove and Install
SMCS - 4151-010
Removal Procedure
Table 1
Required Tools
A
477-0910 Electric Hydraulic Pump Gp (115V) 1
477-0911 Electric Hydraulic Pump Gp (230V) 1
8S-7620 Base As 1
8S-7610 Base As 1
396-9840 Cylinder As 2
8S-7615 Pins 2
B
283-1495 Stands 2
8S-7611 Tubes 2
8S-7615 Pins 2
C 439-3941 Link Brackets 4
D
8B-7557 Threaded Adapter 1
1P-0074 Slide Hammer Puller Gp 1
E 386-6032 Lever Puller Hoist 1
F 386-6030 Lever Puller Hoist 1
1/6
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1. Separate the track.
2. Use Tooling (A) in order to raise the machine. Raise the machine in order to remove the
track rollers. Use Tooling (B) in order to support the machine.
2/6
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3. Attach Tooling (C) and a suitable lifting device to track roller frame (1) . The weight of
track roller frame (1) is approximately 2340 kg (5160 lb). Remove bolts (2) . Remove caps
(3) .
4. Remove guards (6) . Repeat for the opposite side.
5. Remove sprocket segment (4) in order to remove the frame. Refer to Disassembly and
Assembly , "Sprocket Segment - Remove and Install". Remove plate (5) .
6. Use Tooling (D) in order to remove retainer (7) .
3/6
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7. Attach Tooling (C) , Tooling (E) , Tooling (F) , and a suitable lifting device to track roller
frame (1) . The weight of track roller frame (1) is approximately 2340 kg (5160 lb).
8. Remove bolts (8) . Remove plate (9) .
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9. Remove thrust washer (10) . Remove the track roller frame.
10. Remove seal (11) .
5/6
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11. Remove bearings (12) and (13) from the track roller frame.
Installation Procedure
1. Install track roller frame (1) in the reverse order of removal.
a. Lubricate seal (11) with lubricant that is being sealed.
Note: Do not reuse bolts (8) . Because bolts (8) have been torqued to a yield, the bolts
can only be used one time. Failure to replace bolts (8) with new bolts (8) could result
in damage to the machine.
b. Tighten bolts (8) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
c. Tighten bolts (2) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
Fri Aug 27 00:29:38 UTC+0800 2021
6/6
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Shutdown SIS
Previous Screen
i04948309
Pivot Shaft - Remove and Install
SMCS - 4153-010
Removal Procedure
Table 1
Required Tools
A 154-6185 Forcing Bolts 2
B 5P-3931 Anti-Seize Compound -
Start By:
A. Remove the track roller frame.
1/3
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1. Attach a suitable lifting device to pivot shaft (2). The weight of pivot shaft (2) is
approximately 90 kg (200 lb). Remove bolts (1). Use Tooling (A) to remove pivot shaft (2).
Remove pivot shaft (2) .
2. Remove ring (3) from pivot shaft (2) .
Installation Procedure
1. Install pivot shaft (2) in the reverse order of removal.
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a. Raise the temperature of ring (3). Install ring (3) to Dimension (X). Dimension (X) is
375.5 mm (14.78 inch).
b. Apply Tooling (B) to the flange of pivot shaft (2) prior to installation.
c. Tighten bolts (1) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).
Fri Aug 27 00:30:34 UTC+0800 2021
3/3
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Shutdown SIS
Previous Screen
i05873371
Idler - Remove and Install
SMCS - 4159-010
Removal Procedure
Table 1
Required Tools
A 1U-9200 Lever Puller Hoist 1
B 138-7574 Link Bracket 1
C
316-6042 Puller Gp 1
6V-3175 Double Acting Cylinder 1
350-7768 Electric Hydraulic Pump Gp (115 V) 1
350-7769 Electric Hydraulic Pump Gp (230 V) 1
D 5P-3931 Anti-Seize Compound -
E 1P-0510 Driver Gp 1
Start By:
A. Separate the track over the idler.
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
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exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
1. Remove guards (1) .
2. Reposition idler (2) and the yoke assembly. Attach Tooling (A) , Tooling (B) , and a
suitable lifting device to idler (2) and the yoke assembly. The combined weight of idler (2)
and the yoke assembly is approximately 254 kg (560 lb). Remove idler (2) and the yoke
assembly.
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3. Reposition idler (2) and the yoke assembly, as shown.
4. Attach Tooling (B) and a suitable lifting device to yoke assembly (4) . The weight of yoke
assembly (4) is approximately 45 kg (100 lb). Remove bolts (3) and yoke assembly (4) .
5. Attach a suitable lifting device to idler (2) . The weight of idler (2) is approximately 209 kg
(460 lb). Remove idler (2) .
3/7
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Caterpillar Cat D7E LGP TRACK-TYPE TRACTOR (Prefix TJA) Service Repair Manual (TJA00001 and up).pdf

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Caterpillar Cat D7E LGP TRACK-TYPE TRACTOR (Prefix TJA) Service Repair Manual (TJA00001 and up).pdf