545 Wheel Skidder Machine Systems Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00602135

1. Install O-ring (33) and backup ring (33) on capsule (34). Install O-ring seal (35) on hose fitting (36).

2. Install plunger (30), spring (31), capsule (34), and hose fitting (36) in the pilot valve. Tighten hose fitting (36) to a torque of 45 N·m (33 lb ft).

3. Repeat Steps 1 and 2 for the remaining capsules.
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   Illustration 2	g00602134

4. Install retainer (23), spring seat (25), retaining ring (26), spring (27), shim (28), and spring seat (29) on plunger (24).
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   Illustration 3	g00602128

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

5. Use Tooling (A) to compress the spring on plunger assembly (21).

6. Install retaining ring (22).
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   Illustration 4	g00602126

7. To assemble the capsule, install plunger assembly (21), O-ring seal (19), and U-cup seal (20) in cap (18).
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   Illustration 5	g00602115

8. Install spring (16) and capsule (17) in the pilot valve.

9. Repeat Steps 4 through 8 for the remaining capsules.
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   Illustration 6	g00602112

10. Install gaskets (15).
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    Illustration 7	g00602111

11. Install the swivel and bolt (14) on plate (13).
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    Illustration 8	g00602110

12. Install plate (13).
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    Illustration 9	g00601920

13. Install plate (12) and bolts (11). Tighten the bolts (11) to a torque of 35 N·m (26 lb ft).
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    Illustration 10	g00601919

14. Install plate (10) and jam nut (3) on pilot valve (4).

    Note: Steps 15 through 17 are for assembling the control handle, if necessary.

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    Illustration 11	g00601918

15. Solder the wires onto the switches. Install nuts (8) in order to secure switches (9) on plate (7).
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    Illustration 12	g00601917

16. Install plate (7), the washers, and three screws (5) in control handle (1).

17. Install buttons (6) on control handle (1).
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    Illustration 13	g00601916

18. Install control handle (1) on pilot valve (4). Push up boot (2) and tighten jam nut (3) to a torque of 65 N·m (48 lb ft).

End By:

1. Install the pilot valve for the grapple. Refer to Disassembly and Assembly, "Joystick Control and Pilot Valve (Grapple) - Install" for the machine that is being serviced.