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Product: TRACK-TYPE TRACTOR

Model: D3C III TRACK-TYPE TRACTOR 4KS
Configuration: D3C & D3C LGP, XL Series III Hystat Tractors 4KS00001-UP (MACHINE) POWERED BY 3046 Engine

Disassembly and Assembly

D3C, D4C AND D5C SERIES III HYSTAT TRACK-TYPE TRACTOR MACHIN
Media Number -SENR1255-00 Publication Date -01/06/1997 Date Updated -11/10/2001

Hydraulic Control Valve

SMCS - 5051-010; 5051-017

Remove & Install Hydraulic Control Valve

Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component containing fluids. Refer to "Tools
And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local regulations and mandates.

Hot oil and components can cause personal injury. Do not allow hot oil
or components to contact the skin. Be sure that the engine and
components are cool enough to touch with your bare hand prior to
performing any service work.

NOTE: Place identification marks on all lines, hoses, wires and tubes for installation purposes. Cap
and plug all lines, hoses and tubes to prevent fluid loss and contaminants from entering the system.

1. Drain oil from the hydraulic tank into a suitable container for storage or disposal. Capacity of the
hydraulic tank is 83 liters (21.9 U.S. Gal).
2. Remove four bolts (2) and washers, and remove plate assembly (1) from the machine.

3. Open access panel. (3).

4. Disconnect four rod ends (4).

5. Remove tube assemblies (5) and (6).

6. Disconnect four tube assemblies (7), (8), (9) and (10).

7. Disconnect three tube assemblies (11), (12) and (13), and hose assembly (14).

8. Remove three bolts (15) and remove hydraulic control valve (16) from the machine.

NOTE: Install in reverse order.

9. Fill the hydraulic tank. Consult the Operation And Maintenance Manual for proper quantity and
type of fluid. After the tank is filled to the proper level, check for leaks and correct if necessary. Start
the engine and purge the system of any air to insure that all systems operate properly.

Disassemble & Assemble Hydraulic Control Valve

Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component containing fluids. Refer to "Tools
And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local regulations and mandates.

Hot oil and components can cause personal injury. Do not allow hot oil
or components to contact the skin. Be sure that the engine and
components are cool enough to touch with your bare hand prior to
performing any service work.
NOTE: Place identification marks on all lines, hoses, wires and tubes for installation purposes. Cap
and plug all lines, hoses and tubes to prevent fluids loss and contaminants from entering the system.

NOTE: Do not mix the components of the pilot control valve during disassembly and assembly.

Start By:

a. remove hydraulic control valve

1. Clean the outside of the hydraulic control valve to reduce to possibility of contamination in the
system. Place identification on all parts for correct assembly.

2. Remove three nuts (1) from the rods.

3. Remove manifold (2) from the rods.

4. Remove relief valve group (3) and O-ring seal (4) from the manifold.

5. Disassemble the relief valve group as follows:

a. Remove valve body (5) from housing (6) and remove O-ring seal (7), cap (8) and nut (9).

b. Remove four O-ring seals (10), (11), (12), (13) and ring seal (14).

c. Remove spring (15), plunger assembly (16), O-ring seal (17), and ring seal (18).

6. Remove tilt control valve (19) from the rods.

7. Disassemble the tilt control valve as follows:

a. Remove spring (20), valve (21), and O-ring seal (22).

b. Remove two screws (23) and plate (24).

c. Remove wiper (25) and O-ring seal (26).

d. Remove two screws (27) and cap (28).

e. Remove valve spool assembly (29).

f. Remove O-ring seal (30), wiper (31), and plate (32).

NOTE: Use care not to cause damage to the spool surface.

g. Carefully place the flat end of the spool assembly in a vise.

h. Remove screw (33), spring (35), and two retainers (34) and (36).

8. Remove lift control valve (37) from the rods.

9. Disassemble the lift control valve as follows:

a. Remove spring (38), valve (39), and O-ring seal (40).

b. Remove two screws (41) and plate (42).

c. Remove wiper (43) and O-ring seal (44).

d. Remove two screws (45), two spacers (46), and valve spool assembly (47).

e. Remove check valve (48).

f. Remove spacer (50) and two O-ring seals (49) and (51) from valve spool assembly 47).

g. Remove ring (52) from valve spool assembly (47).

h. Remove cap (53) and cap (54).

NOTE: Use care not to cause damage to the valve spool assembly.

i. Carefully place the flat end of the valve spool assembly in a vise.
 Sleeve (55) has spring force behind it.

j. Press the center ball downward and remove sleeve (55).

k. Remove ball (56), four balls (57) and spring (58) (not shown).

l. Install a 6mm × 25mm bolt (59) and nut (60) in the hole in end (61).
m. Using a 1 inch, six point socket, remove end (61).

n. Remove spring (63), and two retainers (62) and (64)from valve spool (65).

10. Remove angle control valve (66) from the rods.

11. Repeat step (7) for the disassembly on the angle control valve.

12. Remove ripper control valve (67) from the rods.

13. Disassemble the ripper control valve as follows:

a. Remove spring (68), valve (69) and O-ring seal (70).

b. Remove two screws (73) and plate (72).

c. Remove relief valve (71).

d. Remove cap (74), nut (75) and two O-ring seals (76) and (77).

e. Remove wiper (78 and O-ring seal (79).

f. Remove two O-ring seals (80) and (81).

g. Remove adjustment screw (86), retainer (85), spring (84) retainer (83), and poppet (82) from relief
valve (71).

h. Remove two screws (89) and cap (88).

i. Remove check valve (87).

j. Remove O-ring seal (91) from check valve (87).

k. Remove valve spool assembly (90).

l. Remove O-ring seal (94), wiper (93) and plate (92) from the valve spool assembly.

NOTE: Use care not to cause damage to the valve spool surface.
m. Carefully place the flat end of the valve spool assembly in a vise.

n. Remove screw (95), retainer (96), spring (97) and retainer (98).

14. Remove three rods (99) from housing (100).

NOTE: The following steps are for the assembly of the hydraulic control valve.

NOTE: Insure that all parts a completely clean prior to assembly. All internal parts should have a
light coating of oil prior to assembly. Inspect all parts for wear or damage and replace any worn or
damaged parts.

15. Install three rods (99) in housing (100).

NOTE: Assemble the ripper control valve as follows:

a. Carefully put the flat end of the valve spool in a vise.

b. Install retainer (98), spring (97), retainer (96) and screw (95). Tighten screw (95) to a 10 ± 1 N·m
(7.5 ± 1 lb ft).
c. Install plate (92), wiper (93), and O-ring seal (94).

d. Install valve spool assembly (90) into the ripper control valve.

e. Install O-ring seal (91) onto check valve (87).

f. Install check valve (87) into the ripper control valve and tighten two screws (89) to a torque of 10 ±
1 N·m (7.5 ± 1 lb ft).

h. Install poppet (82), retainer (83), spring (84), retainer (85), and adjustment screw (86) into relief
valve (71).
j. Install O-ring seal (79) and wiper (78).

k. Install nut (75), cap (74) and two O-ring seals (76) and (77). Tighten cap (74) and nut (75) to a
torque of 61 ± 6 N·m (45 ± 4 lb ft).

l. Install plate (72) and two screws (73).

m. Install relief valve (71) and tighten to a torque of 54 ± 14 N·m (40 ± 10 lb ft).

17. Install ripper control valve (67) onto the rods.

Assemble the angle control valve as follows:

a. Carefully place the flat end of the valve spool in a vase.

b. Install retainer (36), spring (35), retainer (34) and screw (33). Tighten screw (33) to a torque of 10
± 1 N·m (7 ± 1 lb ft).

c. Install plate (32), wiper (31), and O-ring seal (30).

d. Install valve spool assembly (29).

e. Install cap (28) and two screws (27). Tighten two screws (27) to a torque of 7 N·m (5 lb ft).

f. Install O-ring seal (26) and wiper (25).

g. Install plate (24) and two screws (23).

h. Install O-ring seal (22), valve (21), and spring (20).

19. Install angle control valve (66) onto the rods.

20. Assemble the lift control valve as follows:

a. Carefully put the flat end of the valve spool in a vise.

b. Install retainer (64, spring (63), retainer (62) and cap (61) onto spool (65).

c. Install a 6mm × 25mm bolt (59) and nut (60) in the hole in cap (61).

d. Use a six point inch socket and tighten cap (61) to a torque of 10 ± 1 N·m (7 ± 1 lb ft).

e. Install spring (58) not shown, and ball (56).

f. Hold sleeve (55) in your hand and press the ball in the center downward.

g. Install four balls (57), and drop sleeve (55) into position.
h. Install cap (54) and cap (53) onto the valve spool assembly.

i. Install ring (52) onto valve spool assembly (47).

j. Install two O-rings (49) and (51), and spacer (50) onto valve spool assembly (47).

k. Install check valve (48) into the lift control valve. Tighten the check valve (48) to a torque of 54 ±
14 N·m (40 ± 10 lb ft).

l. Install two spacers (46), valve spool assembly (47), and two screws (45). Tighten two screw (45) to
a torque of 7 ± 1 N·m (5 ± .5 lb ft).
m. Install O-ring seal (44) and wiper (43).

n. Install plate (42) and two screws (41).

o. Install O-ring seal (40), valve (39) and spring (38).

21. Install lift control valve (37) onto the rods.

22. Repeat step (18) for the assembly of the tilt control valve.

23. Install tilt control valve (19) onto the rods.

24. Assemble the relief valve as follows:

a. Install ring seal (18), O-ring seal (17), plunger assembly (16) and spring (15).

b. Install ring seal (14) and four O-ring seals (13), (12), (11) and (10).

c. Install valve body (5) onto valve body (6).

d. Install nut (9) and cap (8). Tighten nut (9) and cap (8) to a torque of 14 ± 2N·m (10 ± 1 lb ft).

e. Install O-ring seal (7).

25. Install relief valve (3) into the manifold. Tighten relief valve (3) to a torque of 54 ± 14 N·m (40 ±
10 lb ft).
26. Install O-ring seal (4) to the manifold.

27. Install manifold (2) onto the rods.

Install three nuts (1) to the rods. Tighten the nuts to a torque of 45 ± 4 N·m (33 ± 3 lb ft).

End By:

a. install hydraulic control valve

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