D9R Cab Installation {1408, 7177, 7301, 7325} Caterpillar

Track-Type Tractor

D9R (S/N: HWH1-UP; WDM1-UP)

Introduction

Illustration 1	g06025020
(A) Cab (B) Operator platform

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction contains the necessary procedure to install a cab to a D9R operator platform, and also contains instructions to install ROPS and Lights on the D9R.

Estimated Installation Times

Safety Section

Show/hide table

Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

Approximate Weights

Required Parts

Cab Preparation and Mounting

Illustration 2	g06025286

1. Install one 1/2-13 threaded guide rod to each side of the operator platform in location (B) as shown in Illustration 2.
   Show/hide table

   Illustration 3	g06025297

2. Add a lifting eye at location (A). Use an appropriate lifting device at locations (A) and (C) and lift the cab. The weight of the cab is approximately 475 kg (1050 lb).
   Show/hide table

   Illustration 4	g06025322
   (8) 5P-5727 Seal (Red) (9) 5P-57275P-5727 Seal (Blue) (10) 9P-2262 Seal (Green) (11) 9P-2261 Seal (Pink)

3. Apply seals (8), (9), (10), and (11) as shown in Illustration 4.

4. Lower the cab onto the tractor until it is approximately 300 mm (12 inch) above the operator platform.
   Show/hide table

   Illustration 5	g06025302

5. Connect harnesses and fluid lines (D) in the washer bottle box.

6. Finish lowering the cab onto the operator platform.

7. Remove threaded guide rods.
   Show/hide table

   Illustration 6	g06021914
   (1) 3E-6919 Bolt (2) 3E-6920 Bolt (3) 7X-3392 Hard Washer

   Note: Do not tighten any cab mounting bolts until all cab mounting bolts have been started from Step 8 through Step 13.

8. Secure the left side of the cab to the operator platform with four bolts (1), two bolts (2), and eight washers (3).
   Show/hide table

   Illustration 7	g06021826
   (1) 3E-6919 Bolt (3) 7X-3392 Hard Washer

9. Secure the rear portion of the cab to the operator platform using three bolts (1) and six washers (3).
   Show/hide table

   Illustration 8	g06021909
   (1) 3E-6919 Bolt (2) 3E-6920 Bolt (3) 7X-3392 Hard Washer

10. Secure the right side of the cab to the platform with four bolts (1), two bolts (2), and eight washers (3).
    Show/hide table

    Illustration 9	g06021928
    (4) 3E-6918 Bolt (5) 7X-0618 Hard Washer

11. Secure front of cab with three bolts (4) and three washers (5). Connect the wiring harnesses.
    Show/hide table

    Illustration 10	g06021950

12. Secure the lower left corner of the cab with three bolts (6) and three washers (7).

13. Repeat Step 12 for the lower right-hand corner of the cab.

14. Tighten all bolts installed in Step 8 through Step 13 to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Cab Interior

Show/hide table

Illustration 11	g06022108
(1) 8E-6877 Cover (2) 6V-3884 Hex Socket Screw (3) 9X-2038 Washer

1. Install cover (1) over the dash bracket using two screws (2) and two washers (3).
   Show/hide table

   Illustration 12	g06022179
   (4) 133-5082 Air Duct (LH) (5) 6J-0488 Screw (6) 030-8535 Locking Bolt (7) 5P-1075 Hard Washer (46) 8E-3250 Gasket

2. Install left- hand duct assembly (4) with gasket (46) to the cab with two screws (5), one bolt (6), and three washers (7).
   Show/hide table

   Illustration 13	g06022136
   (8) 8E-7238 Cover (RH) (9) 8T-1572 Hex Socket Screw

3. Install cover 8 with two screws (9).
   Show/hide table

   Illustration 14	g06022170
   (4) 144-3579 Air Duct (RH) (5) 6J-0488 Screw (6) 030-8535 Locking Bolt (7) 5P-1075 Hard Washer (11) 6V-3884 Hex Socket Screw (46) 8E-5975 Gasket

4. Feed the heater/AC harness up through duct assembly (10). Connect the harness and fasten the heater/AC controls to duct assembly (10) with two screws (11).

5. Install right- hand air duct (10) with gasket (47) to cab using two screws (5), one bolt (6), and three washers (7).
   Show/hide table

   Illustration 15	g06022217
   (12) 8E-7364 Boot

6. Assemble boots (12) to the dozer control lever and the ripper control lever.
   Show/hide table

   Illustration 16	g06022287
   (13) 3E-8680 Handle Switch (14) 7X-0448 Nut (15) 8C-8514 Screw (16) 4B-4863 Washer

7. Install handle (13) to dozer control lever with one nut (14), two screws (15), and two washers (16).
   Show/hide table

   Illustration 17	g06022296

8. Install knob (17) to the ripper control lever with two jam nuts (18).
   Show/hide table

   Illustration 18	g06022310
   (19) 7M-0706 Knob (20) 3T-7292 Sleeve (21) 8P-7824 Knob (49) 8P-7826 Knob

9. Install knob (19) and plate (20) to the transmission lever.

10. Install two knobs (21) and (49) to the steering control levers with two bolts (22).
    Show/hide table

    Illustration 19	g06022506
    (23) 6Y-3007 Knob

11. Assemble knob (23) to the brake lever.
    Show/hide table

    Illustration 20	g06025348
    (9) 8T-1572 Hex Socket Screw (28) 105-3380 Cover

12. Install cover (28) with three screws (9).
    Show/hide table

    Illustration 21	g06022639
    (9) 8T-1572 Hex Socket Screw (24) 8E-7239 Cover (Rear) (25) 7G-4823 Strap (26) 7G-4824 Strap (27) 6Y-0206 Retainer

13. Install rear cover (24) with two screws (9).

14. Attach straps (25) and (26) with two retainers (27) and four screws (9).
    Show/hide table

    Illustration 22	g06022966
    (9) 8T-1572 Hex Socket Screw (29) 8E-7242 Cover

15. Install cover (29) to the left-hand side with two screws (9).
    Show/hide table

    Illustration 23	g06023003
    (3) 9X-2038 Washer (9) 8T-1572 Hex Socket Screw (30) 8E-7235 Tray

16. Install tray (30) to the rear right-hand side with two screws (9) and two washers (3).
    Show/hide table

    Illustration 24	g06023047
    (11) 6V-3884 Hex Socket Screw (27) 6Y-0206 Retainer (31) 7T-1890 Cab Air Filter Element (32) 134-3992 Door As (33) 8E-1356 Knob As (34) 8E-7791 Strap (35) 154-3079 Strap (48) 8E-5959 Seal

17. Install filter (31) behind the seat.

18. Install door assembly (32) and seal (48) over filter (31) with two knobs (33).

19. Attach straps (34) and (35) with two retainers (27) and four screws (11) as shown in Illustration 24.
    Show/hide table

    Illustration 25	g06023154
    (36) 8Y-6388 Vent Louver As (37) 104-2091 Flat Head Screw (38) 7T-4306 Louver As

20. Install four louver assemblies (36) with two screws (37) each. Louver assemblies (36) should be installed so that the turning wheel faces upwards.

21. Install louver assembly (38) to position near steering controls with two screws (37). Louver assembly (38) should be installed so that the turning wheel faces upwards.
    Show/hide table

    Illustration 26	g06023170
    (39) 107-0266 Cab Air Filter Element

22. Install filter (39) on the left-hand side of the cab behind the seat.

23. Place lower floor mat (40) and upper floor mat (41) on the cab floor.
    Show/hide table

    Illustration 27	g06023196
    (42) 147-0852 Plate (LH) (43) 6D-6812 Knob As (44) 7X-0603 Hard Washer

24. Install plate (42) to the left-hand side of the cab with two knobs (43) and four washers (44).

25. Repeat Step 24 for the right-hand side using plate (45), two knobs (43), and four washers (44).

Installing the Defroster Fan Group

Note: The 184-6730 Defroster Fan Gp is only used in the 382-7669 Cab Ar (Arctic) and the 382-7682 Cab Ar (Steel Mill). For 382-7668 Cab Ar (Standard), this section is not used.

Show/hide table

Illustration 28	g06025636
(1) 3E-7835 Defroster Fan Gp (2) 5K-0906 Bolt (3) 8T-4224 Hard Washer (B) Harness

1. Install fan group (1) to the dash bracket with four bolts (2) and four washers (3).

2. Connect Harness (A) to fan group (1).
   Show/hide table

   Illustration 29	g06025684
   (4) 8E-6877 Cover (5) 6V-3884 Hex Socket Screw (6) 9X-2038 Washer

3. Install cover (4) to the dash with two screws (5) and two washers (6).
   Show/hide table

   Illustration 30	g06025739
   (1) 3E-7835 Defroster Fan Gp (2) 5K-0906 Bolt (3) 8T-4224 Hard Washer (A) Harness

4. Install fan group (1) to the cab bracket at the right-hand rear corner of the cab with four bolts (2) and four washers (3).

5. Connect harness (B) to fan group (1).

Cab Exterior and ROPS

Show/hide table

Illustration 31	g06023213
(1) 6Y-3682 Handhold (2) 5P-2228 Bolt (3) 8T-4223 Hard Washer

1. Install grab handles (1) to the cab with four bolts (2) and four washers (3).

2. Clean all rust and debris from the mounting surfaces of the ROPS.

1. Using an appropriate lifting device, lift rollover assembly (4) and place on the ROPS mounts. The ROPS weighs approximately 500 kg (1100 lb).
   Show/hide table

   Illustration 32	g06023234

2. Secure rollover assembly (4) with 12 bolts (5) and 12 washers (6). Tighten bolts (5) to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft).

3. Install handle (7) to roll over assembly (4) with two bolts (8) and two washers (9).

Fender Lights

Show/hide table

Illustration 33	g06023428
(1) 153-2073 Flood Lamp Gp (2) 8E-3241 Bracket As (3) 111-8314 Bracket As (4) 5M-3062 Bolt (5) 5P-1075 Hard Washer (6) 5P-2955 Bolt (7) 8T-4224 Hard Washer (8) 6V-8189 Nut

1. Attach each lamp (1) to bracket (2) with the following parts:

   • One bracket assembly (3)

   • One bolt (4)

   • One washer (5)

   • One bolt (6)

   • Two washers (7)

   • One nut (8)
   Show/hide table

   Illustration 34	g06023520
   ( 1) 153-2073 Flood Lamp Gp (5) 5P-1075 Hard Washer (9) 8T-2502 Bolt

2. Attach bracket (2) to the left- hand front fender with one bolt (9) and one washer (5).

3. Connect the lighting harness to lamp (1).

4. Repeat Step 2 and Step 3 for the right- hand front fender light.
   Show/hide table

   Illustration 35	g06023793
   (2) 8E-3241 Bracket As (5) 5P-1075 Hard Washer (9) 8T-2502 Bolt

5. Install bracket (2) to the right- hand rear fender with one bolt (9) and one washer (5).

6. Connect lighting harness to lamp (1).

7. Repeat Step 5 and Step 6 for the left- hand rear fender light.