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

Assembly Procedure

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

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Illustration 1	g00484534

2. Install retaining ring (35) in the groove on shaft (34). Install bearing (36) on shaft (34) with a press. Install the bearing until the bearing makes contact with the retaining ring. Install the other retaining ring (35) on the opposite side of bearing (36) .

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Illustration 2	g00484536

3. Install inner race (37) on the end of shaft (34). Install the inner race until the inner race is seated against the shoulder on the shaft.

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Illustration 3	g00485905

4. Apply a thin coat of 5P-3413 Pipe Sealant on surfaces (Y) on the body of the travel motor. Install lip type seal (38) in the body of the travel motor. Install the lip type seal with the lip of the seal outward. Be sure that the lip type seal makes contact with the counterbore in the body of the travel motor.

Note: Slowly rotate shaft assembly (34) during the installation in order to make sure that the shaft assembly does not bind in the body of the travel motor.

5. Apply clean hydraulic oil on the lip of lip type seal (38). Use a press to install shaft assembly (34) in the body of the travel motor. Slowly rotate the shaft during the installation in order to make sure that the shaft does not bind. Make sure that the bearing on the shaft makes contact with the counterbore in the body of the travel motor.

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Illustration 4	g00485913

Note: Locating pin (32) (not shown) on each key (31) is not centered. Install keys (31), as shown. This position prevents damage to barrel assembly (23). The keys must be installed in the key's original location in the body of the travel motor.

6. Install the two locating pins and two keys (31) in the body of the travel motor, as shown.

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Illustration 5	g00484527

7. Install cam plate (30) in the body of the travel motor in the plate's original location. Make sure that the two pistons and two keys (31) in the body of the travel motor engage properly with the cam plate.

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Illustration 6	g00484525

8. Install nine springs (29) in the barrel. Install spacer (26) and guide (27) on the barrel.

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Illustration 7	g00484502

9. Install piston shoe assemblies (25) in the piston shoe assembly's original bores in shoe retainer (24) .

10. 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 the piston shoe assembly's original bore in barrel (26) .

Note: Make sure that cam plate (30) is correctly engaged with the two pistons in the body of the travel motor prior to installing barrel assembly (23). When the body of the travel motor is tilted to allow the installation of barrel assembly (23), cam plate (30) can slide off the two pistons. The remaining parts of the travel motor can be assembled with the cam plate in the incorrect position. Extensive damage will result from incorrect installation of cam plate (30). Use the procedure in Steps 11 and 12 to prevent damaging the travel motor.

11. Apply clean hydraulic oil on the sliding surfaces of the cam plate, on the piston shoe assemblies and on the splined shaft of the travel motor.

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Illustration 8	g00485953

12. Route a piece of strong string through an opening for the cam plate tension adjusters. Route the string over the cam plate and through the opposite opening for the cam plate tension adjusters. Hold the string taut in order to keep cam plate (30) correctly engaged with keys (31). Position the body of the travel motor on the body's side. Do not release the tension on the string at this time. Install barrel assembly (23) on the shaft. Pull the string out of the body of the travel motor. It may be necessary to pull the barrel assembly and the piston shoe assemblies away from the cam plate slightly in order to release the string.

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Illustration 9	g00485966

13. Check the condition of the O-ring seal and the ring that is used on piston guide (19). If the O-ring seal or the ring is worn or damaged, use new parts for replacement. Install O-ring seal (21) and ring (22) on piston guide (19), as shown.

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Illustration 10	g00484441

14. Put the body of the travel motor in a vertical position.

15. Apply clean hydraulic oil on five friction plates (20) and the four steel plates. Alternate the friction plates and the steel plates in the body of the travel motor. Start with a friction plate and end with a friction plate.

16. Apply 1U-6396 O-Ring Assembly Compound on the O-ring seal and the ring on piston guide (19). Install the piston guide in the body of the travel motor. Install the piston guide until the piston guide makes contact with the counterbore in the body of the travel motor.

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Illustration 11	g00485978

17. Make sure that brake piston (14) is thoroughly clean and free of dirt and debris. Check the condition of rings (16) and (18). Check the condition of O-ring seals (15) and (17). If the rings or the O-ring seals are worn or damaged, use new parts for replacement. Install rings (16) and (18) on the brake piston, as shown. Install O-ring seals (15) and (17) on the brake piston, as shown. Apply 1U-6396 O-Ring Assembly Compound on the rings and O-ring seals.

18. Apply a thin coat of hydraulic oil on the surfaces of piston (14) which contact the body of the travel motor. Install piston (14) in the body of the travel motor by hand. It may be necessary to use a soft faced hammer to seat the piston correctly.

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Illustration 12	g00486008

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Illustration 13	g00484408

19. Install washers (13) in piston (14), as shown.

20. Check the condition of three O-ring seals (12). If the O-ring seals are worn or damaged, use new parts for replacement. Install O-ring seals (12) in the body of the travel motor, as shown.

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Illustration 14	g00484562

21. Install the two pistons and two stoppers (39) in the body of the travel motor. Tighten the stoppers to a torque of 140 ± 14 N·m (105 ± 10 lb ft).

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Illustration 15	g00484406

22. Check the condition of the O-ring seals that are used on fittings (10). If the O-ring seals are worn or damaged, use new parts for replacement. Install the O-ring seals on fittings (10). Apply 5P-3413 Pipe Sealant on the threads of fittings (10). Install the fittings in the head, as shown.

23. Install plugs (11) in the head. Tighten each plug to a torque of 15 ± 2 N·m (11 ± 1 lb ft).

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Illustration 16	g00484404

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Illustration 17	g00484402

24. Apply a thin coat of 9S-3263 Thread Lock Compound on the threads of the two check valves. Install the check valves in the head.

25. Install seat (7), poppet (8) and spring (9) in the head at location (X) .

26. Check the condition of O-ring seal (6). If the O-ring seal is worn or damaged, use a part for replacement. Install O-ring seal (6) in the head, as shown.

27. Install bearing (3) in the head until the bearing makes contact with the counterbore in the cover. Apply 1U-6396 O-Ring Assembly Compound on port plate (4). Install the port plate in the original position on the motor cover.

28. Use shims (5) so that the following requirements are met.

    1. The travel motor output shaft does not rotate with an applied torque of 440 N·m (325 lb ft) or more. The brake release port is open to the air.

    2. The travel motor output shaft rotates with an applied torque of 29 N·m (21 lb ft) or less. The brake release port is pressurized to 780 kPa (115 psi) with both the inlet port and the outlet port open to the hydraulic tank.

Note: It may be necessary to remove head (2) several times in order to determine the correct thickness of shims (5). The shims are used to adjust the rolling torque of the travel motor output shaft.

29. Apply a thin layer of 5P-0960 Molybdenum Grease on shims (5). Install the shims on the head. The grease will hold the shims in place during the installation of the head. Install the head on the body of the travel motor.

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Illustration 18	g00484393

30. Put head (2) in the head's original position on the travel motor. Install ten socket head bolts (1) that hold the head in place. Tighten the ten socket head bolts to a torque of 175 ± 18 N·m (130 ± 13 lb ft).

31. 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 travel motor.

32. 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 Operation and Maintenance Manual for the correct oil specification.

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