Disassembly Procedure
Show/hide table
Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| (A) |
1P-2420 |
Transmission Repair Stand |
1 |
| (B) |
1P-1859 |
Pliers |
1 |
| (C) |
1P-1863 |
Pliers |
1 |
| (D) |
138-7575 |
Link Bracket |
2 |
Show/hide table
|
| 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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
|
Show/hide table
|
| NOTICE |
|---|
Failure to properly assemble parts or failure to follow established procedures can lead to damage to the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed into the same location. Never force parts during assembly. Keep parts clean and lubricated. |
|
Show/hide table
|
| NOTICE |
|---|
Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
|
Note: If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information is available to analyze failures for piston pumps and motors. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".
Note: Inspect all parts. If any parts are worn or damaged use new parts for replacement. The installation of used parts during reconditioning is acceptable. Reuse and salvage information is available on piston pumps. Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure.
Show/hide table
|
 |
|
| Illustration 1 | g00633207 |
- Thoroughly clean the outside of the travel motor prior to disassembly. Fasten travel motor (1) to Tool (A). The weight of the travel motor is 125 kg (275 lb).
- Put an alignment mark across all housings of the travel motor for assembly purposes.
- Disconnect tube assembly (2) .
Show/hide table
 |
Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. |
 |
Show/hide table
|
 |
|
| Illustration 2 | g00633208 |
Show/hide table
|
 |
|
| Illustration 3 | g00633209 |
- Remove two socket head bolts (3) from the brake cover that are 180 degrees from each other. Replace these two bolts with bolts that are slightly longer in length. The two longer bolts will retain the brake cover when the remaining socket head bolts (3) are removed.
- Evenly remove the remaining socket head bolts (3) that hold the brake cover in position. Remove the two longer bolts (3). Remove brake cover (4) from the brake assembly.
Show/hide table
|
 |
|
| Illustration 4 | g00633210 |
- If necessary, remove brake adjusting screws (5) from the brake cover.
Show/hide table
|
 |
|
| Illustration 5 | g00633212 |
- Remove brake assembly (6) from the head assembly.
Show/hide table
|
 |
|
| Illustration 6 | g00633213 |
Note: There is an inner spring and an outer spring in each spring set.
- Remove spring sets (7) from the brake piston.
Show/hide table
|
 |
|
| Illustration 7 | g00633214 |
- Turn the brake housing to the other side. Remove O-ring seal (8) .
Show/hide table
|
 |
|
| Illustration 8 | g00633216 |
- Use two suitable forcing screws (9) in order to remove brake piston (10) from the brake housing.
Show/hide table
|
 |
|
| Illustration 9 | g00633217 |
- Remove discs (11) and plates (12) .
Show/hide table
|
 |
|
| Illustration 10 | g00633218 |
- Remove O-ring seal (13) .
- Use Tool (B) in order to remove retaining ring (14). Remove gear (15) .
Show/hide table
|
 |
|
| Illustration 11 | g00633219 |
- Use Tool (C) in order to remove retaining ring (16) .
- Remove the nut and bushing (17) from the rod assembly.
- Remove four socket head bolts (18) that hold the head assembly to the motor housing.
Show/hide table
|
 |
|
| Illustration 12 | g00633220 |
- Fasten Tool (D) and a hoist to head assembly (19), as shown. Carefully remove the head assembly from the motor housing. The weight of the head assembly is 25 kg (55 lb).
Show/hide table
|
 |
|
| Illustration 13 | g00633221 |
- Remove thrust plate (20) from the head.
Show/hide table
|
 |
|
| Illustration 14 | g00633223 |
- Remove O-ring seal (22) from the head.
- Remove bearing (23) from the head.
- Remove pin (21) from the head.
Show/hide table
|
 |
|
| Illustration 15 | g00633224 |
- Remove O-ring seal (25) from the motor housing.
- Turn the motor housing on the side, as shown.
Note: Keep the components together, while you remove the barrel assembly from the motor housing. All parts in the barrel assembly must be reinstalled in the original locations.
- Carefully remove barrel assembly (24) from the motor housing so the components do not come apart.
- Disassemble barrel assembly (24), as follows:
Show/hide table
|
 |
|
| Illustration 16 | g00633225 |
- Place identification marks on piston assemblies (27), retainer (26), and barrel (28). Remove piston assemblies (27), and retainer (26) from barrel (28) .
- Separate piston assemblies (27) from retainer (26) .
Show/hide table
|
 |
|
| Illustration 17 | g00633227 |
- Remove guide (29) from the barrel.
Show/hide table
|
 |
|
| Illustration 18 | g00633228 |
Note: Take note of the shims (30) that are positioned on the barrel for installation purposes.
- Remove shims (30) from the barrel.
Show/hide table
|
 |
|
| Illustration 19 | g00633230 |
- Remove adjusting screw (31) from the motor housing. Remove the O-ring seal from the adjusting screw.
- Remove swashplate assembly (32) from the motor housing.
- Disassemble the swashplate assembly, as follows:
Show/hide table
|
 |
|
| Illustration 20 | g00633231 |
- Remove plate (33) .
Show/hide table
|
 |
|
| Illustration 21 | g00633232 |
- Remove three pins (34) from the plate.
- Remove two screws (35) .
- Remove plate (36) .
- Remove two plungers (37) .
Show/hide table
|
 |
|
| Illustration 22 | g00633235 |
- Use Tool (B) in order to remove retaining ring (38) that holds shaft assembly (39) in the motor housing.
Show/hide table
|
 |
|
| Illustration 23 | g00633238 |
- Use a soft faced hammer in order to remove shaft assembly (39) from the motor housing in the direction that is shown.
- Disassemble shaft assembly (39), as follows:
Show/hide table
|
 |
|
| Illustration 24 | g00633239 |
- Remove O-ring seal (40) from cover (41) .
- Remove cover (41) from the shaft.
Show/hide table
|
 |
|
| Illustration 25 | g00633241 |
- Remove lip seal (42) from cover (41) .
Show/hide table
|
 |
|
| Illustration 26 | g00633243 |
- Use Tool (C) in order to remove retaining ring (43) that holds bearing (44) in position on the shaft.
Show/hide table
|
 |
|
| Illustration 27 | g00633245 |
- Put the shaft in a press, as shown. Press the shaft out of bearing (44) .
Show/hide table
|
 |
|
| Illustration 28 | g00633246 |
- Remove two screws (47) and two bearings (46) from the motor housing. Remove two bushings (45) from the motor housing.
