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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 Travel Pumps

SMCS - 5070-010; 5070-017

Remove & Install Hydraulic Travel Pumps

Start By:

a. remove batteries*

b. remove rear guard (belly guard)*

c. remove floor plates*

NOTE: * This procedure can be found in 3046 Engine Supplement for the D4C Tractor, Publication
number SENR1248.

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 the hydraulic tank group. Capacity is approximately 83 liters (22 U.S. Gal).

2. Loosen clamps (2) and disconnect hose assembly (1). Disconnect tube assembly (3).

3. Remove tube assemblies (4) and (5). Remove three bolts (6) and washers and remove block
assembly. (7).
4. Remove cotter and pin (8), and disconnect rod end (10) from lever (9).

5. Remove two bolts (12) and washers and reposition bracket (11) and the cable assembly out of the
way.

6. Remove hose assembly (13). Disconnect hose assemblies (14), (15) and (16).

7. Disconnect wire connector (17). Remove two bolts (18) and washers and remove backup alarm
(21).

8. Remove three bolts (19) and washers, and remove plate (20).

9. Remove eight bolts (23) and washers and remove plate assembly (22).
10. Remove four bolts (25) and washers, and remove rear power take off cover (24).

11. Disconnect hose assembly (26). Disconnect hose assembly (29) and (30) and reposition for
removal later. Remove hose assemblies (27) and (28) from the pumps and the motors.

NOTE: The cab has been removed for picture purposes.

12. Disconnect hose assemblies (32) and (33), and remove elbow (31).

13. Remove clip (34) and remove hose assembly (29).

14. Remove hose assembly (35).

15. Disconnect hose assembly (37) and elbow (36) at the pump. Disconnect hose assembly (38).

16. Remove clip (39), and remove hose assembly (30).

17. Disconnect hose assemblies (40) and (41).

18. Remove eight bolts (43) and washers and remove two elbows (42).
19. Remove nut (45) and washer. Loosen nuts (44).

20. Place tooling (A) in position as shown. Use wood blocks for clearance and leveling.

21. Remove nut (46) and washer. Loosen nuts (47).

22. Slowly disengage the pumps form the motor. As the pumps disengage, remove nuts (44) and
washers and nuts (47). Lower the pumps to the ground and remove from the rear of the machine.
Weight of the pumps is 150 kg (330 lb).

NOTE: Install in reverse order.

23. Fill the hydraulic tank with hydraulic oil to the correct level. See the Operation And Maintenance
Manual for the correct filling procedure.

End By:

a. install batteries*

b. install rear guard (belly guard)*

c. install floor plates*

NOTE: * This procedure can be found in 3046 Engine Supplement for the D4C Tractor, Publication
number SENR1248.

Disassemble & Assemble Hydraulic Travel Pump

Start By:

a. remove hydraulic travel motor

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.

1. Thoroughly clean the pump prior to any disassembly.

2. Remove protective caps (2) from all of the adjustment screws. Remove O-ring (3).

3. Place identification marks on pilot pump assembly (4) and valve group (1) for installation purposes.
The pilot pump must be installed in its original position.

4. Remove four screws (5) and pilot assembly (4) from valve group (1).

NOTE: Step 5 and 6 are for the disassembly of the pilot pump assembly.
5. Remove plate (6), shaft (7), gears (9) and (10), and O-ring (11) from pilot pump housing (12). If
necessary, remove key (8).

6. Remove sleeve (13) from pilot pump housing (12).

7. Loosen nut (14) and remove adjustment screw (15) from hydraulic pump (16).

8. Place identification mark on hydraulic pump (16) and valve group (1) for installation purposes. The
valve group must be installed to its original position.

9. Remove four screws (17) and carefully separate valve group (1) from hydraulic pump (16).
10. Remove port plate (18), O-ring (19) and O-ring (20) from the valve group.

11. Remove two valves (21) from the valve group.

NOTE: Steps 12 through 16 are for the disassembly of valves (21).

12. Remove O-ring (22), back up ring (23), and O-ring (24) from valve section (25).

13. Separate valve section (25) and (26).

14. Remove poppet (27), piston (28), and spring (29) from valve section (25).

15. Remove seal (30) and O-ring (31) from valve section (26).

16. Remove piston (32), spring (33), adjustment screw (34), bushing (35), O-ring (37), and nut (36)
from valve section (26).

NOTE: Repeat step 12 through 16 for the disassembly of the second valve.
17. Remove plug (38) and three plugs (39) from the valve group (1).

18. Remove valves (40) and (41) from valve group (1).

19. Remove O-ring (42), piston (43), collar (44) and spring (45) from the valve group.

NOTE: Steps 20 through 29 are for the disassembly of valve (41).

20. Remove nut (46) and O-ring (48) from the valve.

21. Loosen screw (47) and remove lever (49) from the valve.

22. Loosen screw (50) and remove stop collar (51) from the valve.
23. Remove snap ring (52) and orifice (53) from the valve.

24. Remove nut (54) and washer (56), and unscrew controller pipe assembly (55) from the valve.

25. Remove shims (57), washer (58) and spring (59) from valve (41).

26. Remove circlip (60) and snap ring (61) from the controller pipe assembly (55).
27. Remove ring (64), controller pipe (62), spring (63), two collars (65), and piston (66) from the
controller pipe assembly.

28. Remove three screws (67) and cover (68) from the valve.

29. Remove O-rings (69) and (70), washer (71), trunnion (72), screw (73), spring collar (74) and
valve body (75).

30. Remove fitting (76) and valve (77) from valve group (1).

NOTE: Steps 31 through 32 are for the disassembly of valve (77).

31. Remove O-ring (78), poppet seat (79), valve piston (80), bushing (81), and piston (82) from valve
(77).

32. Remove control piston (83), spring (85), O-ring (86) and two spring collars (84) from valve (77).

33. Remove four plugs (87), test port (88), and two fittings (89) and (92) from valve group (1).

34. Remove sleeves (91) and (92) from valve group.

35. Carefully remove barrel assembly (93) from hydraulic pump (16).

36. Remove plate (94), piston assemblies (95), ball (96) and spring shims (97) from the barrel
assembly.

37. Remove four fittings (98), (99), (10) and (101) from the hydraulic pump.

38. Remove snap ring (102) and shaft (103) from the hydraulic pump.
39. Remove swash plate (105), guide block (104), two bearings (106), two pins (107) and two liners
(108) from the hydraulic pump.

40. Remove two plugs (110) and two pins (109) from the hydraulic pump.

41. Remove snap ring (13), seal (111), and spacer (112) from the hydraulic pump.

42. Remove snap ring (115) and bearing (114) from the hydraulic pump.
43. Remove four screws (117), cover (116) and plug (118). Remove four screws (119) and cover
(120) from the hydraulic pump.

44. Remove O-ring (121) from cover (116), and four O-rings (122) from cover (120).

45. Remove four screws (124), plug (125), and piston assembly (123), from hydraulic pump (16).

46. Remove nut (126), cover (127), O-rings (128) and (129), and ring (130) from piston assembly
(123).
47. Put piston assembly (123) in a press. Using tooling (A), slightly compress as shown. Remove two
retaining collars (132) and snap ring (131) from the piston assembly.

48. Remove two collars (133) and (136), and two springs (134) and (135) from piston assembly (123).

49. Place piston assembly (123) in a press and apply compression to remove snap ring (137).

50. Remove remaining piston assembly (123) from piston (138).

51. Place piston assembly (123) in a press and apply compression to remove two retaining collars
(139).

52. Remove two collars (140 and (143), two springs (141) and (142) and rod (144) from the piston
assembly.

53. Remove two bushings (145) from the hydraulic pump.

NOTE: The following steps are necessary for assembly.

54. Install two bushings (145) into the hydraulic pump.

55. Install two collars (140) and (143), two springs (141) and (142), and rod (144).

56. Place valve assembly (123) in a press and apply compression to install two retaining collars (139).

57. Install valve assembly (123) into piston (138).

58. Apply compression to install snap ring (137) into valve assembly (123).
59. Install two collars (133) and (136), two springs (134) and (135) into valve assembly (123).

60. Put piston assembly (123) in a press. Using tooling (A), slightly compress as shown. Install two
retaining collars (132) and snap ring (131).

61. Install O-ring (129), ring (130), O-ring (128), cover (127), and nut (126) onto valve assembly
(123).

62. Install valve assembly (123) into hydraulic pump (16). Install four screws (134) and plug (125).
63. Install O-ring (121) to cover (116) and install four O-rings (122) to cover (120).

64. Install cover (120) and four screws (119). Install cover (116) and four screws (117). Install plug
(118) to the hydraulic pump.

65. Install two liners (108) in the hydraulic pump.

66. Assemble guide block (104). two bearings (106) and two pins (107) onto swashplate (105).

NOTE: Fasten each bearing to the swashplate with a rubber band as shown. The rubber bands will
hold the bearings in position during installation of the sashplate in the pump housing.
67. Carefully install swashplate (105) into the pump housing. Slide guide block (104) into the slot in
piston (138).

68. Use a pair of scissors to cut each rubber band and slide each rubber band out of the pump housing.

69. Visually inspect the position of two pins (107) through the openings in the side of the pump
housing. Each pin should be centered over an opening.

70. Use a screwdriver to install two pins (109). Each slotted pin (109) must engage with a slot. Install
two plugs (110) into the pump housing.

71. Install spacer (112), bearing (114), and snap ring (102) on shaft (103).
72. Install shaft (103) into the pump housing.

73. Install plate (94), piston assemblies (95), ball (96) and spring shims (97) to the barrel assembly.

74. Take a measurement of the barrel and plate as shown. Dimension (X) should be 117.4 mm as
displayed on the above art. Adjust the shims as required to meet this specification.
75. While holding barrel assembly (93) together by hand, turn it over as shown.

76. Fasten a piece of nylon cord around the piston assemblies (95) as shown. The nylon cord will be
used to hold barrel assembly (93) together during installation in the pump housing.

77. Carefully install barrel assembly (93) over the shaft in the pump housing. Make sure none of the
parts of the barrel assembly have come out of position during installation. Remove the nylon cord
from around the barrel assembly.

78. Install two sleeves (91) and (92) into valve group (1).

79. Install four plugs (87), test port (88) and two fittings (89) and (90) to valve group (1).
NOTE: Steps 82 and 83 are for the assembly of valve (77).

80. Install control piston (83), spring (85), O-ring (86) and two spring collars (84) in valve (77).

81. Install O-ring (78), poppet seat (79), valve piston (80), bushing (81), and piston (82) to valve (77).

82. Install fitting (76) and valve (77) to valve group (1).

NOTE: Steps 85 through 94 are for the assembly of valve (41).

83. Install spring collar (74), screw (73), trunnion (72), washer (71), and two O-rings (70) and (69) on
valve body (75).
84. Install cover (68) and three screws (67 on the valve.

85. Assemble ring (64), controller pipe (62), spring (63), two collars (65) and piston (66), forming the
controller pipe assembly.

86. Install circlip (60) and snap ring (61) on the controller pipe assembly (55).

87. Install shims (57), washer (58) and spring (59) on valve (41).
88. Screw controller pipe assembly (55) on the valve. Install washer (56) and nut (54) on the valve.

89. Install orifice (53) and snap ring (52) on the valve.

90. Install stop collar (51) and tighten screw (50) on the valve.

91. Install lever (49) and tighten screw (47) on the valve.

92. Install O-ring (48) and nut (46) on the valve.

93. Install valve (41) on the valve group.

94. Install spring (45), collar (44), piston (43), O-ring (42) and valve (40) on the valve group.

95. Install three plugs (39) and plug (38) on valve group (1).

NOTE: Steps 98 through 102 are for the assembly or valve (21).

96. Install piston (32), spring (33), adjustment screw (34), bushing (35), O-ring (37) and nut (36) on
valve section (26).
97. Install O-ring (31), and seal (30) on valve section (26).

98. Install poppet (27), piston (28) and spring (29) on valve section (25).

100. Install valve section (25) on valve section (26). Install O-ring (22), backup ring (23) and O-ring
(24) on valve section (25).

NOTE: Repeat steps 98 through 100 for the assembly of the second valve.

101. Install two valves (21) in the valve group.

102. Install port plate (18), O-ring (19) and O-ring (20) in the valve group.
103. Install valve group (1) and four screws (17) to hydraulic pump (16). Do not tighten screws at this
time.

104. Align notch in port plate (18) with the opening in the hydraulic pump.

105. Tighten four screws (17) and install adjustment screw (15) and nut (14) to the hydraulic pump.

106. Place the hydraulic pump in a press and apply compression to shaft (103) and install snap ring
(115) in the hydraulic pump.
107. Install seal (111) and snap ring (113) in hydraulic pump (16).

108. Install four fittings (98), (99), (100) and (101) in the hydraulic pump.

NOTE: Steps 111 and 112 are for the assembly of the pilot pump assembly (4).

109. Install sleeve (13) in pilot pump housing (12).

110. Install O-ring (11), gears (9) and (10), key (8), shaft (7) and plate (6) in pilot pump housing (12).

111. Install pilot pump assembly (4) and four screw (5) in the hydraulic pump.

112. Install O-ring (3) and protective caps (2) in the hydraulic pump.
End By:

a. install hydraulic travel pump

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