D3K2, D4K2 and D5K2 Track-Type Tractors Power Train Caterpillar

Removal Procedure

Start By:

1. Remove the bottom guard.

1. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.
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   Illustration 1	g01367600

2. Remove support assemblies (1). Remove floor mat (2).
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   Illustration 2	g01367603

3. Remove bolts (3). Remove plate assembly (4).
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   Illustration 3	g02728599

4. Loosen the clamps and disconnect tubes (5).
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   Illustration 4	g02896039

5. Disconnect hose assemblies (6) and (7). Disconnect fitting (8). Move the hose assemblies out of the way.
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   Illustration 5	g02888549

6. Disconnect harness assemblies (17). Remove the bolt and clip (23).

7. Disconnect hose (9). Disconnect hose assemblies (12), (16), (18), and (22).

8. Disconnect tube assemblies (13), (14), (15), (19), (20), and (21).

9. Remove bolts (10) and hydraulic block (11).

Installation Procedure

1. Install hydraulic block assembly (11) in the reverse order of removal.

Disassembly Procedure

Start By:

1. Remove the hydraulic block.

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Illustration 6	g02890037

1. Remove bolts (1) and the bracket. Remove solenoid valve (2). Repeat for the other solenoid valve.

2. Remove fitting (3) and the O-ring seal. Repeat for the other fitting.

3. Remove plug (4) and the O-ring seal.
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   Illustration 7	g02892176

4. Remove O-ring seals (5) from solenoid valve (2). Repeat for the other solenoid valve.
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   Illustration 8	g02891276

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   Illustration 9	g02891139

5. Remove relief valve (8). Remove elbow (6) and the O-ring seal. Remove elbow (7) and the O-ring seal. Remove elbow (9) and the O-ring seal.

6. Remove plug (10) and the O-ring seal. Remove plug (11) and the O-ring seal.
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   Illustration 10	g02892040

7. Remove backup rings (15) and O-ring seal (12) from relief valve (8). Remove backup rings (16) and O-ring seal (13). Remove O-ring seal (14).
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   Illustration 11	g02892039

8. Remove plug (17) and the O-ring seal. Remove elbow (18) and the O-ring seal. Remove check valve (19). Remove fitting (20) and the O-ring seal. Remove fitting (21) and the O-ring seal.
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   Illustration 12	g02892136

9. Remove O-ring seal (22), O-ring seal (24), and backup ring (23) from check valve (19).
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   Illustration 13	g02892041

10. Remove fitting (25) and the O-ring seal. Remove fitting (26) and the O-ring seal. Remove plug (27) and the O-ring seal. Remove fitting (28) and the O-ring seal. Remove elbow (29) and the O-ring seal. Remove plug (30) and the O-ring seal.
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    Illustration 14	g02892216

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

11. Remove fitting (31) and the O-ring seal from hydraulic block (35). Remove plug (32) and the O-ring seal.

12. Remove plug (36) and the O-ring. Remove fitting (37) and the O-ring seal.
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    Illustration 15	g02892101

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    Illustration 16	g02893221

13. Remove plug (33), spring (39), and poppet (40) from hydraulic block (35). Remove O-ring seal (38).

Assembly Procedure

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Illustration 17	g02892216

1. Install the O-ring seal and fitting (37) in hydraulic block (35). Install the O-ring seal and plug (36). Tighten plug (36) to a torque of 2.26 ± 0.11 N·m (20.00 ± 1.00 lb in). Install the O-ring seal and plug (34). Tighten plug (34) to a torque of 2.25 ± 0.11 N·m (20.00 ± 1.00 lb in).

2. Install the O-ring seal and plug (32). Tighten plug (32) to a torque of 2.37 ± 0.23 N·m (21 ± 2 lb in). Install the O-ring seal and fitting (31).
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   Illustration 18	g02892101

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   Illustration 19	g02893221

3. Install O-ring seal (38) on plug (33). Install poppet (40), spring (39), and plug (33) in hydraulic block (35). Tighten plug (33) to 100 ± 5 N·m (74 ± 4 lb ft).
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   Illustration 20	g02892041

4. Install the O-ring seal and plug (30). Tighten plug (30) to a torque of 45 ± 3 N·m (33 ± 2 lb ft). Install the O-ring seal and elbow (29). Install the O-ring seal and fitting (28). Install the O-ring seal and plug (27). Tighten plug (27) to a torque of 45 ± 3 N·m (33 ± 2 lb ft). Install the O-ring seal and fitting (26). Install the O-ring seal and fitting (25).
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   Illustration 21	g02892136

5. Install backup ring (23), O-ring seal (24), and O-ring seal (22) on check valve (19)
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   Illustration 22	g02892039

6. Install the O-ring seal and fitting (21). Install the O-ring seal and fitting (20). Install check valve (19). Tighten check valve (19) to a torque of 100 ± 5 N·m (74 ± 4 lb ft). Install the O-ring seal and elbow (18). Install the O-ring seal and plug (17). Tighten plug (17) to a torque of 2.37 ± 0.23 N·m (21 ± 2 lb in).
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   Illustration 23	g02892040

7. Install O-ring seal (14). Install O-ring seal (13) and backup rings (16). Install O-ring seal (12) and backup rings (15) on relief valve (8).
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   Illustration 24	g02891139

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   Illustration 25	g02891276

8. Install the O-ring seal and plug (11). Tighten plug (11) to a torque of 2.26 ± 0.11 N·m (20 ± 1 lb in). Install the O-ring seal and plug (10). Tighten plug (10) to a torque of 2.37 ± 0.23 N·m (21 ± 2 lb in).

9. Install the O-ring seal and elbow (9). Install the O-ring seal and elbow (7). Install the O-ring seal and elbow (6). Install relief valve (8) and tighten relief valve (8) to a torque of 100 ± 5 N·m (74 ± 4 lb ft).
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   Illustration 26	g02892176

10. Install O-ring seals (5) on solenoid valve (2). Repeat for the other solenoid valve.
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    Illustration 27	g02890037

11. Install the O-ring seal and plug (4). Tighten plug (4) to a torque of 5.76 ± 0.34 N·m (51 ± 3 lb in).

12. Install the O-ring seal and fitting (3). Repeat for the other fitting.

13. Install solenoid valve (2), the bracket, and bolts (1). Tighten bolts (1) to a torque of 14.24 ± 0.68 N·m (10.5 ± 0.5 lb ft).

End By:

1. Install the hydraulic block.