CIPI UNDERCARRIAGE Arrangements: 9Q-5262, 191-4041, and 204-9207 Caterpillar

Type "A" Travel Brake Valve

Start By:

1. Remove the travel brake valve and travel motor. Refer to Disassembly and Assembly, "Travel Brake Valve - Remove" in this manual.

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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.

1. Thoroughly clean the outside of the travel brake valve and travel motor prior to disassembly.

2. Put an alignment mark across the cover of the travel brake valve and the case assembly of the travel motor for assembly purposes.

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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.

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Illustration 1	g00850637

3. Remove two connectors (7). Remove fittings (1) and (6). Remove the O-ring seals from the fittings and connectors.

4. Remove plug (5) and the O-ring seal from the cover. Remove two plugs (2) and the O-ring seals from the cover.

5. Remove crossover relief valve (3) (forward travel) and crossover relief valve (4) (reverse travel) from the cover.

6. Use the following procedure to disassemble crossover relief valves (3) and (4) .
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   Illustration 2	g00850655

   1. Remove sleeve (10) from the crossover relief valve. Remove two backup rings (12) and O-ring seal (9) from the sleeve.

   2. Remove O-ring seal (8) from the crossover relief valve.

   3. If necessary, remove nut (11) from the crossover relief valve.

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Illustration 3	g00850661

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Illustration 4	g00850665

7. Remove displacement charge valve (13) from the cover. Remove two plugs (14), spring (16) and valve (15) from the cover. Remove O-ring seal (17) from each plug.

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Illustration 5	g00850671

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Illustration 6	g00850672

8. Use the following procedure to remove counterbalance valve (19) from the cover.

   1. Remove two socket head bolts (18) that are diagonal to each other. Loosen the other two socket head bolts (18) evenly in order to release the spring force behind cover (22). The spring force will be released prior to complete removal of the two socket head bolts.

   2. Remove cover (22), spring (21), seat (23), and valve (20) from the cover. Remove O-ring seal (24) from the cover.
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   Illustration 7	g00850677

   3. Remove four socket head bolts (18), cover (22), spring (21), and the seat from the other side of the cover. Remove O-ring seal (24) from the cover.

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Illustration 8	g00850681

9. Remove eight socket head bolts (26) and cover (25) from the case assembly.

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Illustration 9	g00850683

10. Mark the position of valve plate (27) in relation to the cover. Remove valve plate (27) from the cover.

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Illustration 10	g00850685

11. Remove bearing (28) and four locating pins (29) from the cover.

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Illustration 11	g00850686

12. Remove three small O-ring seals (32) from the case assembly. Remove O-ring seal (30) from the case assembly. Remove eight springs (31) from pistons (33) .

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Illustration 12	g00850723

13. Fasten Tool (A) to the case assembly of the travel motor, as shown. Apply approximately 525 kPa (75 psi) of shop air pressure to brake release port (Y). Make sure that the shop air pressure is free of water. Brake piston (33) will move up the piston guide, and out of the case assembly of the travel motor.

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Illustration 13	g00850724

14. Remove O-ring seals (36) and (35) from brake piston (33). Remove backup rings (34) and (37) from brake piston (33) .

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Illustration 14	g00850728

Note: Do not allow the components of barrel assembly (38) to come apart during the removal from the case assembly of the travel motor. All of the components in the barrel assembly must be reinstalled in the component's original location.

15. Place the case assembly on the case assembly's side. Remove barrel assembly (38) from the case assembly.

16. Use the following procedure to disassemble barrel assembly (38) .
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    Illustration 15	g00850730

    1. Put identification marks on nine piston assemblies (39) for assembly purposes. Identification marks are used to identify the piston assembly's location in barrel (41). Remove the nine piston assemblies and retainer plate (40) as a unit from the barrel. Separate the piston assemblies from the retainer plate.
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    Illustration 16	g00850732

    2. Remove bushing (42) and three pins (43) from the barrel.
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    Illustration 17	g00850736

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    Illustration 18	g00850737

    Note: Ring (45) and ring (46) are different sizes.

    3. Put barrel (41) in a press. Install a suitable size drive plate from Tool (B). The diameter of the drive plate should be slightly smaller than ring (45). Put a slight amount of compression on ring (45) with the press. Remove retaining ring (44) with Tool (C). Slowly release the spring compression. Remove ring (45), spring (47), and ring (46) from barrel (41) .

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Illustration 19	g00850739

17. Remove swashplate (48) from the case assembly.

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Illustration 20	g00850743

18. Put identification marks on two pistons (49) and two balls (52) for assembly purposes. Remove the two pistons and balls from the case assembly.

19. Use a soft faced hammer to remove shaft assembly (50) from the case assembly. Tap on the shaft assembly from the back side of the case assembly in order to remove the shaft assembly.

20. Remove race (51) from the end of the shaft.

21. Use a press to remove the shaft out of bearing (53) .

22. Remove the lip seal from the case.

Type "B" Travel Brake Valve

Start By:

1. Remove the travel brake valve. Refer to Disassembly and Assembly, "Travel Brake Valve - Remove" in this manual.

Note: Mark all of the components during the disassembly of the travel brake valve. Make sure that the marks are used during the assembly of the travel brake valve. Do not mix the parts.

1. Thoroughly clean the outside of the travel brake valve prior to disassembly.

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Illustration 21	g00529095

2. Remove plate (1) from travel brake valve (2) .

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Illustration 22	g00529096

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Illustration 23	g00532372
This is an exploded view of brake valve (4) .

3. Remove O-ring seal (3) from travel brake valve (2). Remove brake valve (4) from the travel brake valve.

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Illustration 24	g00532374

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Illustration 25	g00532376
This is an exploded view of brake valve (7) .

4. Remove valve (5) from travel brake valve (2). Remove two check valves (6) from the travel brake valve. Remove brake valve (7) from the travel brake valve. Remove two relief valve (8) from the travel brake valve.