D6N Track-Type Tractor Machine Systems Bulldozer Control Valve - Assemble Caterpillar

Assembly Procedure

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

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Illustration 1	g00989579

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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.

1. Install valve (201) , dowel (202) , spring (203) , seal (204) , and plug (205) .

2. Tighten plug (205) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 2	g00989577

3. Install O-ring seals (198) , shims (197) , and studs (199) into relief valve (200) .

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Illustration 3	g00989576

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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.

4. Install springs (196) and (195) , valve (194) , O-ring seal (193) , and plug (192) .

5. Tighten plug (192) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 4	g00989575

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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.

6. Install valve (191) , O-ring seal (190) , ring (189) , O-ring seal (188) , body (187) , spring (186) , washer (185) , retainer (184) , O-ring seal (183) , and plug (182) .

7. Tighten plug (182) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 5	g00989573

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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.

8. Install valve (171) , plunger (172) , springs (173) and (174) , ring (175) , O-ring seal (176) , housing (177) , poppet (178) , spring (179) , nut (180) , and adjustment screw (181) in housing (170) .

9. Tighten nut (180) to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

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Illustration 6	g00989572

10. Install O-ring seal (166) , ring (167) , O-ring seal (168) , and valve assembly (169) .

11. Tighten valve assembly (169) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 7	g00989571

12. Install ring (160) , O-ring seals (162) and (161) , ring (163) , O-ring seal (164) , and housing (165) .

13. Tighten housing (165) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 8	g00989570

14. Install ball (155) , O-ring seal (156) , ring (157) , O-ring seal (158) , and seat (159) .

15. Tighten seat (159) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 9	g00989569

16. Install O-ring seals (154) , spool (153) , filter (152) , retainer (151) , guard (150) , and bolts (149) .

17. Tighten bolts (149) to a torque of 5.5 ± 1.5 N·m (48.68 ± 13.28 lb in).

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Illustration 10	g00995930

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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.

18. Install O-ring seal (135) , retainer (136) , spring (137) , spacer (138) , retainer (139) , and shaft assembly (140) .

19. Tighten shaft assembly (140) to a torque of 8 ± 1.5 N·m (71 ± 13.27 lb in).

20. Install housing (141) .

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Illustration 11	g00993132

21. Install spring (148) in shaft (148A) . Apply Tooling (A) to ball (147) and balls (146) . Install ball (147) and balls (146) in shaft (148A) .

22. Apply slight pressure to ball (147) in order to ensure that ball (147) is seated against spring (148) .

23. Install piston (142) while you apply pressure to ball (147) .

24. Install gasket (144) , housing (143) and bolts (145) .

25. Tighten bolts (145) to a torque of 70 ± 7 N·m (51 ± 5 lb ft).

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Illustration 12	g00989566

26. Install lift valve (132) , shims (133) , and O-ring seals (134) in valve bank (5) .

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Illustration 13	g00989565

27. Install ring (126) , O-ring seals (128) and (127) , ring (129) , O-ring seal (130) , and housing (131) .

28. Tighten housing (131) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 14	g00989564

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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.

29. Install springs (124) and (125) , valve (123) , O-ring seal (122) , and plug (121) .

30. Tighten plug (121) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 15	g00989563

31. Install ball (116) , O-ring seal (117) , ring (118) , O-ring seal (119) , and seat (120) .

32. Tighten seat (120) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 16	g00989561

33. Install O-ring seals (115) , spool (114) , filter (113) , retainer (112) , guard (111) , and bolts (110) .

34. Tighten bolts (110) to a torque of 5.5 ± 1.5 N·m (48.68 ± 13.28 lb in).

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Illustration 17	g00989559

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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.

35. Install retainer (103) , spring (104) , retainer (105) , spacer (106) , and bolt (107) . Tighten bolt (107) to a torque of 11 ± 2 N·m (97 ± 18 lb in). Install housing (108) and bolts (109) .

36. Tighten bolts (109) to a torque of 11 ± 2 N·m (97 ± 18 lb in).

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Illustration 18	g00989558

37. Install tilt valve (100) , shims (102) , and O-ring seals (101) in valve bank (5) .

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Illustration 19	g00989557

38. Install ring (95) , O-ring seals (97) and (96) , ring (98) , O-ring seal (98A) , and housing (99) .

39. Tighten housing (99) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 20	g00989556

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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.

40. Install valve (85) , plunger (86) , springs (88) and (87) , ring (89) , O-ring seal (90) , housing (91) , poppet (91A) , spring (92) , nut (93) , and adjustment screw (94) in housing (84) .

41. Tighten nut (93) to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

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Illustration 21	g00989555

42. Install O-ring seal (80) , ring (81) , O-ring seal (82) , and valve assembly (83) .

43. Tighten valve assembly (83) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

44. Repeat Steps 40 and 42 for the remaining valve assembly.

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Illustration 22	g00989554

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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.

45. Install springs (78) and (79) , valve (77) , O-ring seal (76) , and plug (75) .

46. Tighten plug (75) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 23	g00989553

47. Install ball (70) , O-ring seal (71) , ring (72) , O-ring seal (73) , and seat (74) .

48. Tighten seat (74) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 24	g00989552

49. Install O-ring seal (69) , spool (68) , filter (67) , retainer (66) , guard (65) , and bolts (64) .

50. Tighten bolts (64) to a torque of 5.5 ± 1.5 N·m (48.68 ± 13.28 lb in).

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Illustration 25	g00989551

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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.

51. Install retainer (57) , spring (58) , retainer (59) , spacer (60) , and bolt (61) . Tighten bolt (61) to a torque of 11 ± 2 N·m (97 ± 18 lb in).

52. Install housing (62) and bolts (63) . Tighten bolts (63) to a torque of 11 ± 2 N·m (97 ± 18 lb in).

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Illustration 26	g00989550

53. Install angle valve (54) , shims (55) , and O-ring seals (56) in valve bank (5) .

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Illustration 27	g00989549

54. Install O-ring seals (51) , plugs (52) , and studs (53) in manifold assembly (48) .

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Illustration 28	g00989548

55. Install manifold assembly (48) on valve bank (5) . Install nuts (50) , shims (49) , and O-ring seal (47) on manifold assembly (48) .

56. Tighten nuts (50) to a torque of 41 ± 5 N·m (30 ± 4 lb ft).

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Illustration 29	g00989547

57. Install ring (41) , O-ring seals (42) and (43) , ring (44) , O-ring seal (45) , and housing (46) .

58. Tighten housing (46) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 30	g00989546

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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.

59. Install valve (31) , O-ring seal (32) , ring (33) , O-ring seal (34) , housing (35) , spring (36) , washer (37) , retainer (38) , O-ring seal (39) , and plug (40) .

60. Tighten housing (35) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 31	g00989545

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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.

61. Install springs (29) and (30) , valve (28) , O-ring seal (27) , and plug (26) .

62. Tighten plug (26) to a torque of 70 ± 7 N·m (52 ± 5 lb ft).

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Illustration 32	g00989544

63. Install ball (21) , O-ring seal (22) , ring (23) , O-ring seal (24) , and seat (25) .

64. Tighten seat (25) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

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Illustration 33	g00989543

65. Install O-ring seal (20) , spool (19) , filter (18) , retainer (17) , guard (16) , and bolts (15) .

66. Tighten bolts (15) to a torque of 5.5 ± 1.5 N·m (48.68 ± 13.28 lb in).

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Illustration 34	g00989542

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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.

67. Install retainer (8) , spring (9) , retainer (10) , spacer (11) , and bolt (12) . Tighten bolt (12) to a torque of 11 ± 2 N·m (97 ± 18 lb in). Install housing (13) and bolts (14) . Tighten bolt (14) to a torque of 11 ± 2 N·m (97 ± 18 lb in).

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Illustration 35	g00989541

68. Install shims (7) and O-ring seals (6) in ripper valve (4) .

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Illustration 36	g00989540

69. Install ripper valve (4) and cover (3) on valve bank (5) .

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Illustration 37	g00989537

70. Install nuts (2) and valve (1) .

71. Tighten nuts (2) to a torque of 41 ± 5 N·m (30 ± 4 lb ft).

End By: Install the bulldozer control valve. Refer to Disassembly and Assembly, "Bulldozer Control Valve - Install".