D7E Track-Type Tractor Power Train Recoil Cylinder - Assemble Caterpillar

Assembly Procedure

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Illustration 1	g03502502

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Illustration 2	g03502403

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).
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   Illustration 3	g03502309

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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   Illustration 4	g03502332

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   Illustration 5	g06012716

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   Illustration 6	g03507586

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".

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   Illustration 7	g03818600

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).
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   Illustration 8	g06012730

10. Secure cylinder (1) to the hydraulic repair bench. Install Tooling (J) and lubricate with Tooling (H).
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    Illustration 9	g06012733

11. Install rod assembly (16) and piston assembly (17) into Tooling (J) and cylinder (1).
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    Illustration 10	g06012812

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).

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    Illustration 11	g03501201

13. Install O-ring seals (15) onto spacer (14).

14. Lubricate O-ring seals (15) with Tooling (H) and install spacer (14) into the cylinder.
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    Illustration 12	g03507637

15. Install O-ring seal (12), and backup ring (11) into head assembly (9). Lubricate O-ring seal (11) with Tooling (H).
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    Illustration 13	g03483582

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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    Illustration 14	g03507647

17. Install O-ring seal (10) onto head (9).
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    Illustration 15	g03507655

18. Add 236.8 mL (8.0 oz) of Tooling (H) through the center hole in head (9) into the cylinder.
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    Illustration 16	g03507682

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.

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    Illustration 17	g03483261

20. Install valve (4) into manifold (5).
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    Illustration 18	g03507666

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    Dry nitrogen is the only gas approved for use in the accumulator. Charging the accumulator with oxygen gas will cause an explosion. This 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.
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    Illustration 19	g03507683

22. Install guard (3) and bolts (2) .
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    Illustration 20	g03501166

23. Install plug (13) into cylinder (1).

End By:

1. Install the recoil cylinder and the track adjuster.