D6K Track-Type Tractor 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	g01222635

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Illustration 2	g01222663

1. Install bearing (76) onto shaft (74). Use Tooling (C) in order to install retaining ring (75) .

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Illustration 3	g01222333

2. Install shaft (74) into the housing.

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Illustration 4	g01222331

3. Use Tooling (A) in order to install retaining ring (73) into the housing.

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Illustration 5	g01222326

4. Install Tooling (F) over the splines of the shaft in order to protect the seal during installation. Carefully install seal (72) into the housing. Remove Tooling (F) .

5. Use Tooling (A) in order to install retaining ring (71) into the housing.

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Illustration 6	g01222321

6. Position cover (70) and install bolts (69) .

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Illustration 7	g01222319

7. Install O-ring seal (68) onto cap (55) .

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Illustration 8	g01222316

8. Install the following items into the control valve: plate (67), spring (66), spring (65) and plate (64) .

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Illustration 9	g01222313

9. Install the following items into the flow control valve: plate (63), spring (62), spring (61), plate (60) and shaft (54) .

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Illustration 10	g01222348

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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.

10. Use a suitable press and apply slight pressure to the plate. Install spacers (59). Use Tooling (D) in order to install retaining ring (58) .

11. Install O-ring seal (57) and retainer (56) onto the shaft.

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Illustration 11	g01222287

12. Install cap (55) and install nut (53) onto shaft (54) .

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Illustration 12	g01222284

13. Install two spacers (52) into control valve (49) .

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Illustration 13	g01222277

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Illustration 14	g01222274

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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.

14. Use Tooling (C) in order to install retaining ring (51) into control valve (49) .

15. Use a suitable press and apply slight pressure to plate (50) in flow control valve (49) .

16. Install retainer (48) into flow control valve (49) .

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Illustration 15	g01222270

17. Position cover (47) and install bolts (46) .

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Illustration 16	g01222265

18. Install bearing races (45) into the housing.

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Illustration 17	g01222264

19. Install bearing (43) and install pin (44) onto swashplate assembly (39). Install bearing (42) and install pin (41) onto swashplate assembly (39). Install guide block (40) onto swashplate assembly (39) .

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Illustration 18	g01222713

20. Position rubber bands around bearing (43) and around bearing (42) in order to keep the bearings from coming loose during Step 21.

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Illustration 19	g01222262

21. Install swashplate assembly (39) into the housing.

22. Remove the rubber bands.

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Illustration 20	g01222342

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Illustration 21	g01222734

23. Install pin (78) into the housing.

    Note: Wire (44) must go into pin (78) .

    Note: Use a screwdriver in order to turn pin (78). Swashplate assembly (39) must move. This will ensure that wire (44) is in pin (78) .

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Illustration 22	g01331700

24. Install cartridges (37), bolts (38), and coils (36). Install O-ring seals (37) and nuts (34) .

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Illustration 23	g01331698

25. Install gasket (33) .

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Illustration 24	g01331697

26. Position valve assembly (32) and install gasket (31) .

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Illustration 25	g01222248

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Illustration 26	g01331633

27. Install O-ring seal (31) and plug (30) onto cover assembly (30) .

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Illustration 27	g01331631

28. Position cover assembly (28). Install bolts (26). Tighten bolts (26) in order to be only finger tight.

29. Install bolt (27) .

30. Tighten bolts (28) .

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Illustration 28	g01331629

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Illustration 29	g01331630

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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.

31. Install shim (23), spring (24) and shim (25) into barrel assembly (22) .

32. Position barrel assembly (22) into a suitable press. Position Tooling (B) against shim (25). Use the press and apply slight compression on spring (24). Use Tooling (A) in order to install retaining ring (21) and slowly release the spring compression.

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Illustration 30	g01222893

33. The steps that follow will determine the correct shim thickness for the lift off limitation adjustment of the rotating group:

    1. Place port plate (8) onto a surface plate. The flat side of the port plate should rest on the surface plate.
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    Illustration 31	g01222901

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    Illustration 32	g01331850

    2. Place Tooling (G) on the inside diameter of port plate (8). The chamfered side faces upward.

    3. Install barrel assembly (22) onto Tooling (G) and port plate (8) .
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    Illustration 33	g01219421

    4. Install Tooling (H) on top of the barrel assembly, as shown.
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    Illustration 34	g01331853

    5. Make sure that all of the shims have been removed from retainer (19). Install the retainer over Tooling (H) .
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    Illustration 35	g01331854

    6. Install retainer plate (18) onto retainer (19) .
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    Illustration 36	g01219424

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    Illustration 37	g00586012

    7. Bolt Tooling (J) and Tooling (K) together. Place Tooling (J) and Tooling (K) on top of the retainer plate, as shown.
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    Illustration 38	g00586047

    8. Use a Vernier scale height gauge, or a similar tool, in order to measure the dimensions in Step 33.i.
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    Illustration 39	g00586062

    9. Measure the distance from the top of the surface plate to the top of Tooling (J). Record this dimension as Dimension (X). Measure the distance from the top of Tooling (J) to the top of retainer plate (18). Record this dimension as Dimension (W).
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       Table 2

       CALCULATION

       Subtract Dimension (W) from Dimension (X) in order to obtain Dimension (Y).

       Dimension (Y) is the Lift Off Limitation Height.

       Note: The correct Lift Off Limitation Height is 99.96 ± 0.10 mm (3.935 ± 0.004 inch). Call this height Dimension (Z).

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       Table 3

       CALCULATION

       Subtract Dimension (Y) from Dimension (Z) in order to obtain the thickness of shim (20). This will provide the correct Lift Off Limitation Height.

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Illustration 40	g01331627

34. Install shims (20). Refer to Step 33.i.

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Illustration 41	g01331626

35. Install retainer (19) on the shim. Install retainer plate (18). Install pistons (17) .

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Illustration 42	g00681514

36. Wrap a piece of nylon string around the pistons, as shown.

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Illustration 43	g01331857

37. Lower rotating group (16) into the housing. Use the nylon string in order to hold the rotating group together during the installation. Remove the string.

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Illustration 44	g01331623

38. Install valve (15) and the O-ring seal. Install cap (14) .

39. Install plug (13) .

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Illustration 45	g01331621

40. Install valve (12) and the O-ring seals.

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Illustration 46	g01331620

41. Install valve (11) and the O-ring seals.

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Illustration 47	g01222185

42. Install O-ring seal (10) and install O-ring seal (9). Install port plate (8) .

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Illustration 48	g01222184

43. Position head assembly (7) and install bolts (6) .

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Illustration 49	g01222182

44. Install O-ring seal (5) .

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Illustration 50	g01222171

45. Install O-ring seal (4). Install coupling (3). Position flange (2) and install bolts (1) .

End By: Install the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Winch) - Install".