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

Type "A" Travel Brake Valve

1. Make sure that all of the components of the travel motor and the travel brake valve are thoroughly clean and free of dirt and debris prior to assembly.

2. Check the condition of all the parts in the travel motor and the travel brake valve. If any of the parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00850743

3. Use Tool (B) in order to install a new lip seal in the case of the travel drive motor. Install the seal until the seal makes contact with the counterbore in the case and with the sealing lip facing toward the inside of the case.

4. Heat bearing (53), and install the bearing on the shaft of the travel motor. Be sure that the bearing seats against the shoulder on the shaft.

5. Heat race (51), and install the race on the end of shaft of the travel motor. Be sure that the race seats against the shoulder on the shaft.

6. Lubricate bearing (53) with clean hydraulic oil. Install shaft assembly (50) in the case of the travel motor. Use a soft faced hammer to seat the shaft assembly in the counterbore in the case.

7. Install two pistons (49) and two balls (52) in the piston's and ball's original locations in the case assembly. Lubricate the pistons and the balls with clean hydraulic oil.

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Illustration 2	g00850739

8. Install swashplate (48) in the case assembly. Be sure that the swashplate engages with the two balls.

9. Use the following procedure to assemble barrel assembly (38) .
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   Illustration 3	g00850736

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   Illustration 4	g00850737

   1. Install ring (46), spring (47), and ring (45) in barrel (41). Put the barrel in a press. Install a suitable size drive plate from Tool (B) on ring (45), as shown. Compress spring (47) until retaining ring (44) can be installed. Use Tool (C) to install retaining ring (44) .
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   Illustration 5	g00850732

   2. Install three pins (43) and bushing (42) on the barrel, as shown.
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   Illustration 6	g00850730

   3. Install nine piston assemblies (39) in retainer plate (40) .

   4. Install the piston assemblies with the retainer plate in the piston assembly's original bores in barrel (41). Be sure that bushing (42) and three pins (43) stay in position during installation of the piston assemblies and retainer plate.

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NOTICE
To avoid damage to components, do not allow the components of the barrel assembly to come apart while being installed in the case assembly of the travel motor.

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Illustration 7	g00850728

10. Place the case assembly of the travel drive on the case assembly's side. Carefully install barrel assembly (38) over the shaft assembly and into the case assembly. Check the components of the barrel assembly and make sure that the components of the barrel assembly are in the correct position.

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Illustration 8	g00850724

11. Install backup rings (34) and (37) in brake piston (33). Install O-ring seals (36) and (35) in brake piston (33). Be sure that the backup rings and the O-ring seals are installed in the positions, as shown. Apply clean hydraulic oil on the backup rings and O-ring seals.

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Illustration 9	g00850686

12. Install piston (33) in the case assembly.

13. Install O-ring seal (30) in the case assembly. Install three O-ring seals (32) in the case assembly.

14. Install eight springs (31) in piston (33) .

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Illustration 10	g00850685

15. Lower the temperature of bearing (28). Install the bearing in the cover. Seat the bearing with Tool (B) .

16. Install four locating pins (29) in the cover.

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Illustration 11	g00850683

17. Install valve plate (27) in the valve plate's original position on the cover.

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Illustration 12	g00850681

18. Put cover (25) in the cover's original position on the case assembly. Install eight socket head bolts (26). Tighten the socket head bolts to a torque of 295 ± 20 N·m (220 ± 15 lb ft).

19. Use the following procedure to install the counterbalance valve in the cover.
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    Illustration 13	g00850677

    1. Install O-ring seal (24) on cover (22). Install the seat, spring (21), cover (22), and four socket head bolts (18) .
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    Illustration 14	g00850672

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    Illustration 15	g00850671

    2. Install O-ring seal (24) on cover (22). Install valve (20), seat (23), spring (21), and cover (22). Install eight socket head bolts (18). Tighten the socket head bolts evenly to a torque of 59 ± 5 N·m (43 ± 4 lb ft).

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Illustration 16	g00850665

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Illustration 17	g00850661

20. Install displacement charge valve (13) in the cover. Install O-ring seal (17) on each plug (14). Install plug (14), valve (15), spring (16), and the other plug (14) in the cover. Be sure that valve (15) and spring (16) are positioned correctly in the cover. Tighten the two plugs to a torque of 50 ± 3 N·m (37 ± 2 lb ft).

21. Use the following procedure to assemble crossover relief valves (3) and (4) .
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    Illustration 18	g00850655

    1. Install two backup rings (12) and O-ring seal (9) in sleeve (10) .

    2. Install O-ring seal (8) on the valve. Install the sleeve on the valve.

    3. Install nut (11) on the crossover relief valve.

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Illustration 19	g00850637

22. Install crossover relief valve (3) and (4) in the cover. Tighten each valve to a torque of 375 ± 20 N·m (270 ± 15 lb ft).

23. Install the O-ring seal on plug (5). Install the plug in the cover, and tighten the plug to a torque of 74 ± 5 N·m (55 ± 4 lb ft).

24. Install the O-ring seal on each plug (2). Install two plugs (2) in the cover, and tighten the plugs to a torque of 17 ± 2 N·m (12 ± 1 lb ft).

25. Install the O-ring seal on fitting (1) and fitting (6). Install fittings (1) and (6) in the cover. Install the O-ring seal on each connector (7). Install the two connectors in the cover.

End By: Install the travel brake valve and travel motors. Refer to Disassembly and Assembly, "Travel Motor - Install" in this manual.

Type "B" Travel Brake Valve

1. Thoroughly clean all of the parts of the travel brake valve prior to assembly.

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Illustration 20	g00532376
This is an exploded view of brake valve (7) .

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Illustration 21	g00532374

2. Install two relief valve (8) in travel brake valve (2). Tighten two relief valves (8) to a torque of 150 ± 12 N·m (110 ± 9 lb ft).

3. Install brake valve (7) in travel brake valve (2). Tighten brake valve (7) to a torque of 240 ± 20 N·m (175 ± 15 lb ft).

4. Install two check valves (6) in travel brake valves (2). Tighten two check valves (6) to a torque of 150 ± 12 N·m (110 ± 9 lb ft).

5. Install valve (5) in travel brake valve (2). Tighten valve (5) to a torque of 20 ± 2 N·m (15 ± 1 lb ft).

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Illustration 22	g00532372
This is an exploded view of brake valve (4) .

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Illustration 23	g00529096

6. Install brake valve (4) in travel brake valve (2). Tighten brake valve (2) to a torque of 20 ± 2 N·m (15 ± 1 lb ft). Install O-ring seal (3) on the travel brake valve.

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Illustration 24	g00529095

7. Install plate (1) on travel brake valve (2) .

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