Usage:
Start By:
a. remove travel brake valves
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
1. Drain the oil from the final drive in a suitable container for storage or disposal. The capacity of the final drive is 16 liters (4.2 U.S. gal).
2. A small amount of oil will drain from hose assemblies (1) and (2) when they are disconnected from the travel motor. Place a drain pan under the travel motor to contain the drain oil. Disconnect hose assemblies (1) and (2) from the travel motor. Put plugs in the end of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.
3. Remove two of the three bolts (3) that hold the travel motor to the final drive.
4. Install Tool (B) in place of two bolts (3). Fasten Tool (A) and a hoist to travel motor (4) as shown. Remove remaining bolt (3) that holds travel motor (4) to the final drive. Carefully pull travel motor (4) out of the final drive. Remove the travel motor from the machine. The weight of the travel motor is 66 kg (145 lb).
5. Remove the O-ring seal from the body of the travel motor.
NOTE: The following steps are for the installation of the travel motor.
6. Thoroughly clean the mating surfaces of the travel motor and the final drive.
7. Check the condition of the O-ring seal used between the travel motor and the final drive. If the O-ring seal is damaged, use a new part for replacement.
8. Install the O-ring seal on the body of travel motor (4). Apply clean hydraulic oil on the O-ring seal.
9. Fasten Tool (A) and a hoist to travel motor (4) as shown. Carefully install the travel motor on Tool (B). Slide the travel motor into the final drive.
10. Install one of the three bolts (3) that hold the travel motor to the final drive. Remove Tool (B), and install two remaining bolts (3).
11. Connect hose assemblies (1) and (2) to the travel motor. Tighten the two hose assemblies to a torque of 80 ± 7 N*m (59 ± 7 lb ft).
NOTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the final drive.
12. Fill the final drive with oil to the correct level.
End By:
a. install travel brake valves
Disassemble & Assemble Travel Motors
Start By:
a. remove travel motors
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
1. Thoroughly clean the outside of the travel motor prior to disassembly. Fasten the travel motor to a suitable holding fixture in a vertical position. The weight of the travel motor is 66 kg (145 lb).
2. Put an alignment mark across the head and body of the travel motor for assembly purposes. The head must be reinstalled in its original position on the travel motor body.
| NOTICE |
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During the removal of head (2) from the travel motor body, Do Not scratch or damage the mating surfaces of the components. |
3. Remove nine socket head bolts (1) and head (2) from the travel motor body.
4. Turn head (2) over, and remove O-ring seal (6), shim(s) (5), port plate (4) and bearing (3) from the head. Remove the two check valve assemblies from the head.
NOTE: There is a retainer located under spring (9). This retainer is a press fit in head (2). Do Not remove the retainer.
5. Install a small diameter rod in hole (X). Tap the rod with a plastic hammer to remove spring (9), poppet (8) and seat (7) from the head.
6. Remove three fittings (10) and four plugs (11) from the head. Remove the O-ring seal from each fitting.
7. Remove three O-ring seals (12) and washer set (13) from the travel motor body.
8. Place a shop towel over brake piston (14). While retaining brake piston (14) by hand, apply shop air pressure (free of water) of approximately 525 kPa (75 psi) to brake release port (Y). Brake piston (14) will move up and out of the piston guide. Remove brake piston (14) from the travel motor body.
9. Remove O-ring seals (15) and (17) and back-up rings (16) and (18) from the brake piston.
10. Remove piston guide (19), five friction plates (20) and four steel plates from the travel motor body.
11. Remove O-ring seal (21) and back-up ring (22) from the piston guide.
| NOTICE |
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Do Not let the components of barrel assembly (23) come apart during the removal from the travel motor body. All of the components in the barrel assembly must be reinstalled in their original location. |
12. Using two large screwdrivers as shown, slowly remove barrel assembly (23) from the travel motor body so the components Do Not fall apart.
13. Shoe retainer (24) and piston show assemblies (25) are not serviced separately. Prior to the removal of the shoe retainer and the piston shoe assemblies from barrel (26), put identification marks on piston shoe assemblies (25) as to their location in shoe retainer (24) and barrel (26). The piston shoe assemblies must be reinstalled in their original bores in the shoe retainer and the barrel.
14. Remove shoe retainer (24) and piston shoe assemblies (25) from barrel (26). Separate the piston shoe assemblies from the shoe retainer.
15. Remove guide (27), spacer (28) and nine springs (29) from the barrel.
16. Remove cam plate (30) from the travel motor body.
17. Remove two keys (31) and two locating pins (32) (not shown) from the travel motor body.
18. Remove O-ring seal (33) from the travel motor body.
19. Using a soft faced hammer, remove shaft assembly (34) from the travel motor body in the direction shown.
20. Remove retaining rings (35) from each side of bearing (36). Push shaft (34) out of bearing (36) with a press.
21. Remove inner race (37) from shaft (34).
22. Remove lip seal (38) from the travel motor body.
23. Remove two stoppers (39) and the two pistons from the travel motor body.
NOTE: The following steps are for the assembly of the travel motor.
24. Make sure all of the components of the travel motor are thoroughly clean and free of dirt and debris prior to assembly.
25. Install retaining ring (35) in the groove on shaft (34). Install bearing (36) on shaft (34) with a press. Install the bearing until it makes contact with the retaining ring. Install the other retaining ring (35) on the other side of bearing (36).
26. Install inner race (37) on the end of shaft (34) until it is seated against the shoulder on the shaft.
27. Apply a thin coat of 5P-3413 Pipe Sealant on surfaces (Y) of the travel motor body. Install lip seal (38) in the body with the lip of the seal facing in as shown. Be sure the seal makes contact with the counterbore in the body after the installation.
| NOTICE |
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During the installation of shaft assembly (34) in the travel motor body, rotate the shaft slowly to be sure it does not bind. |
28. Apply clean hydraulic oil on the lip of lip seal (38). Install shaft assembly (34) in the travel motor body with a press. Rotate the shaft slowly during the installation, making sure it does not bind. Make sure the bearing on the shaft makes contact with the counterbore in the body.
| NOTICE |
|---|
Locating pin (32) (not shown) on each key (31) is not centered. To prevent damage to barrel assembly (23) during the assembly of the travel motor, the keys must be installed as shown in the illustration. Also, the keys must be installed in their original locations in the travel motor body. |
29. Install the two locating pins and two keys (31) in the travel motor body as shown.
30. Install cam plate (30) in the travel motor body in its original position. Make sure the two pistons and two keys (31) in the travel motor body engage properly with the cam plate.
31. Install nine springs (29) in the barrel. Install spacer (28) and guide (27) on the barrel.
32. Install piston shoe assemblies (25) in their original bores in shoe retainer (24).
33. Apply clean hydraulic oil in the bores of the barrel and on piston shoe assemblies (25). Install the piston shoe assemblies with the shoe retainer in their original bores in barrel (26).
| NOTICE |
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Prior to installing barrel assembly (23), make sure cam plate (30) is correctly engaged with the two pistons in the travel motor body. When the travel motor body is tilted to allow the installation of barrel assembly (23), cam plate (30) can slide off of the two pistons. The remaining parts of the travel motor can be assembled with the cam plate out of position, however extensive parts damaged will result. Use the procedure in Steps 34 and 35 to prevent parts damage. |
34. Apply clean hydraulic oil on the sliding surfaces of the cam plate, the piston shoe assemblies and on the splined shaft of the travel motor.
35. Route a piece of strong string through one of the openings for the cam plate tension adjusters, over the sliding surface of cam plate (30), and out the other opening for the cam plate tension adjusters. Hold the string tight to keep cam plate (30) properly engaged with keys (31). While keeping the string tight, put the travel motor body on its side. Do Not release the tension on the string at this time. Install barrel assembly (23) on the shaft as a unit. It may be necessary to pull the barrel assembly and piston shoe assemblies away from the cam plate a small amount to release the string.
36. Check the condition of the O-ring seal and the back-up ring used on piston guide (19). If the O-ring seal or the back-up ring are worn or damaged, use new parts for replacement. Install O-ring seal (21) and back-up ring (22) on piston guide (19) as shown.
37. Put the travel motor body in a vertical position.
38. Apply clean hydraulic oil on five steel plates (20) and the four friction plates. Install the plates in alternating order in the travel motor body. Start with a steel plate and end with a steel plate.
39. Apply 1U-6396 O-ring Assembly Compound on the O-ring seal and the back-up ring on piston guide (19). Install the piston guide in the travel motor body until it makes contact with the counterbore in the body.
40. Make sure brake piston (14) is thoroughly clean and free of dirt and debris. Check the condition of back-up rings (16) and (18) and O-ring seals (15) and (17). If the back-up rings or the O-ring seals are worn or damaged, use new parts for replacement. Install back-up rings (16) and (18) and O-ring seals (15) and (17) on brake piston (14) as shown. Apply 1U-6396 Assembly Compound on the back-up rings and O-ring seals.
41. Apply a thin coat of clean hydraulic oil on the surface of the travel motor body which makes contact with piston (14). Install piston (14) in the travel motor body by hand. It may be necessary to use a soft faced hammer to seat the piston properly.
42. Install washer set (13) in the piston (14) as shown.
43. Check the condition of three O-ring seals (12). If the O-ring seals are worn or damaged, use new parts for replacement. Install three O-ring seals (12) in the travel motor body as shown.
44. Install the two pistons and two stoppers (39) in the travel motor housing. Tighten the stoppers to a torque of 140 ± 14 N*m (105 ± 10 lb ft).
45. Check the condition of the O-ring seals used on fittings (10). If the O-ring seals are worn or damaged, use a new parts for replacement. Install 5P-3413 Pipe Sealant on the threads of fittings (10). Install the fittings in the head as shown.
46. Reinstall plugs (11) in the head. Tighten each plug to a torque of 15 ± 2 N*m (11 ± 1 lb ft).
47. Apply a thin coat of 9S-3263 Thread Lock on the threads of the two check valves that fit in the head. Install the check valves in the head, and tighten them.
48. Install seat (7), poppet (8) and spring (9) in the head at location (X).
49. Check the condition of O-ring seal (6). If the O-ring seal is worn or damaged, use a new part for replacement. Install O-ring seal (6) in the head as shown.
50. Install bearing (3) in the head until it makes contact with the counterbore in the cover. Apply 1U-6396 O-ring Assembly Compound on port plate (4). Install the port plate in its original position on the motor cover.
- a. The travel motor output shaft does not rotate with a torque of 440 N*m (320 lb ft) or more with the parking brake release port open to the air.
- b. The travel motor output shaft rotates with a torque of 29 N*m (21 lb ft) or below when the parking brake release port is pressurized to 780 kPa (115 psi) with both the inlet and the outlet ports open to the hydraulic oil tank.
51. Use shim(s) (5) as required so the following requirements are met:
NOTE: During the following checks, turn the travel motor output shaft in a clockwise direction.
NOTE: It may be necessary to remove head (2) several times in order to determine the correct thickness of shim(s) (5) used to adjust the rolling torque of the travel motor output shaft.
52. Apply a thin layer of 5P-0960 Multipurpose Grease on shim(s) (5). Install the shim(s) on the head. The grease will hold the shim(s) in place during the installation of the head on the travel motor body.
53. Put head (2) in its original position on the travel motor body. Install ten socket head bolts (1) that hold head in place. Tighten the ten socket head bolts to a torque of 175 ± 18 N*m (130 ± 13 lb ft).
54. Check the condition of O-ring seal (32). If the O-ring seal is worn or damaged, use a new part for replacement. Install the O-ring seal in the groove on the outside of the out travel motor body.
| NOTICE |
|---|
To prevent possible damage to the travel motor, the unit should be filled with oil at least up to the fill port prior to operation. Refer to the "Operation & Maintenance Manual" for the correct oil specification. |
End By:
a. install travel motors