Installation of New 123-4610 Conversion Kit for the Flywheel Clutch{1007, 1156} Caterpillar

Installation of New 123-4610 Conversion Kit for the Flywheel Clutch{1007, 1156}

Usage:

D4E 2CB

Track-Type Tractor:: D4E DD SA (PIN: 2CB1); D4E DD SR TT (PIN: 2DJ1-970); D4E DD (PIN: 34C1; 76W1); D4E DD SA (PIN: 7PB1-714); D4E PS SR (PIN: 77W1)

Introduction

This Special Instruction provides the installation procedure for the new 123-4610 Conversion Kit for the flywheel clutch on D4E SR Track-Type Tractors.

Refer to the necessary parts list.

Note: Do not perform any procedure in this Special Instruction until you read the information and you understand the information.

Necessary Parts (Components of 123-4610 Conversion Kit )

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Table 1
Components of 123-4610 Conversion Kit for the Flywheel Clutch
Item	Part Number	Description	Qty
1	123-3628	Adapter flange	1
2	5F-3106	O-ring seal	1
3	9X-8880	Bolt (5/8 inch by 11 by (2 inch))	2
4	5P-8247	Hard washer ((17 mm) by (3.5 mm) by (32 mm))	2
5	123-3629	Gear	1
6	5P-8246	Hard washer ((15.5 mm) by (3.0 mm) by (29 mm))	1
7	5P-0540	Nut ((9/16 inch) by 18)	1
8	123-4606	Gear pump	1
9	2H-3931	O-ring seal	1
10	4F-1450	Stud ((3/8 inch) by 24 by (1 5/8 inch) by (3/8 inch) by 16)	2
11	1B-4203	Nut ((3/8 inch) by 24)	2
12	5M-2894	Hard washer ((10.2 mm) by (2.5 mm) by (18.5 mm))	13
13	123-4830	Tube assembly	1
14	123-3622	Tube assembly	1
15	2M-9780	O-ring seal	1
16	030-7949	Pipe elbow ((7/8 inch) by 14)	1
17	4B-9302	Tube clip ((5/8 inch))	1
18	0S-1594	Bolt ((3/8 inch) by 16 by (1 inch))	8
19	9S-8752	Nut ((3/8 inch) by 16)	2
20	030-7983	Union tee ((7/8 inch) by 14 by (1 1/16 inch) by 12)	1
21	123-3624	Tube assembly	1
22	5P-6416	Pipe elbow ((1 5/16 inch) by 12 by (1 3/16 inch) by 12)	1
23	6V-1903	O-ring seal	1
24	1S-0724	Tube clip ((1 inch))	1
25	5K-5290	Hose assembly	1
26	9M-2904	Hose clamp ((2 inch))	2
27	7S-7602	Gear pump	1
28	1H-8266	Gasket	1
29	0S-1588	Bolt ((3/8 inch) by 16 by (1 1/4 inch))	1
30	123-3627	Support	1

Installation Procedure

Note: Inspect the O-ring seals for wear and for damage. Replace the seals with new seals, if necessary. Make sure that the O-ring seals are clean. Apply clean oil to the surfaces of the seals during assembly.

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Illustration 1	g00604770
2Y-6287 Front Housing Cover (A) cover (B) tube assembly

Remove cover (A) and tube assembly (B) from the 2Y-6287 Front Housing Cover . Replace these components with adapter flange (1) and O-ring seal (2). Use two bolts (3) and use two washers (4) to fasten the adapter flange to the cover.

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Illustration 2	g00604774
123-4606 Gear Pump

Install gear (5) on the 123-4606 Gear Pump with one washer (6) and with one nut (7) .

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Illustration 3	g00604775
123-4606 Gear Pump

Install gear pump (8) and install O-ring seal (9) on flange (1). Use two studs (10), two nuts (11), and two washers (12) to fasten the pump to the adapter flange.

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Illustration 4	g00604779
123-4606 Gear Pump (top view)

Install tube assembly (13) .

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Illustration 5	g00604782
123-4606 Gear Pump and pump lines

Install support (30). Use two bolts (18) and two washers (12) .

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Illustration 6	g00604786
123-4606 Gear Pump and pump lines

Install tube assembly (14) with O-ring seal (15) and with pipe elbow (16) on the 123-4606 Gear Pump . Use tube clip (17), one bolt (18), two washers (12), and one nut (19) .

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Illustration 7	g00604789
3V-3125 Pump lines

Remove bolts (C) and remove flange (D) from the pump line of the 3V-3125 Pump Lines .

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Illustration 8	g00604795
Magnetic screen and hydraulic lines

Connect tube assembly (14) to hose assembly (E) with union tee (20). See Illustrations 6 and 8.

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Illustration 9	g00604797

Install tube assembly (21) with pipe elbow (22) and with O-ring seal (23) on support (30). Use tube clip (24), one bolt (18), one washer (12), and one nut (19) .

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Illustration 10	g00604800
3V-3125 Pump lines

Remove bolts (F), tube assembly (G), and hose assembly (H) .

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Illustration 11	g00604802
7S-7602 Gear pump and hydraulic lines (top view)

Install hose assembly (25) on tube assembly (21). Use hose clamps (26) .

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Illustration 12	g00604804
7S-7602 Gear pump and hydraulic lines (top view)

Replace pump (J) with gear pump (27). Use gasket (28), four bolts (18), bolt (29), and five washers (12) .

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Illustration 13	g00604806
Magnetic screen and hydraulic lines

Remove four bolts (29) in order to replace filter (K) and seal (L) .
Note: Before you start the machine, fill the scavenge pump section with oil. Add the oil through the lines of the magnetic screen.