980L Tier 3 Wheel Loader Machine System Caterpillar

Assembly Procedure

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Illustration 1	g00670525

1. Use the proper equipment to handle bearing cone (54). Raise the temperature of bearing cone (54). Install bearing cone (54) onto shaft assembly (49).
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   Illustration 2	g00670361

2. Use the proper equipment to handle bearing cup (53). Lower the temperature of bearing cup (53) and install bearing cup (53) in pump body (27).
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   Illustration 3	g00670360

3. Inspect the O-ring seals on plugs (52). Replace the O-ring seals, if necessary. Install plugs (52) in pump body (27).
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   Illustration 4	g00670531

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   Illustration 5	g06132889

4. Install retaining ring (50). Use Tooling (A) to install seal (51) (not shown).
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   Illustration 6	g00670298

5. Install shaft assembly (49).

6. Use the following steps to determine the proper preload on the bearings of the pump assembly.
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   Illustration 7	g00669728

   1. Use the proper equipment to handle the bearing cup. Lower the temperature of bearing cup (30) and install the bearing cup in the head assembly.
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      Illustration 8	g00670604
      Typical Example

   2. Install adjustment shim (33) and bearing cone (32) onto shaft assembly (49).
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      Illustration 9	g00670605

   3. Position head assembly (26) onto pump body (27).
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      Illustration 10	g02580696

   4. Use Tooling (C) to measure the distance between the head and the pump housing.

   5. Take measurements at three equal intervals on the surface between the head and the pump housing.

   6. The average of the three dimensions should be between zero and 0.05 mm (0.002 inch).

   7. If necessary, grind adjustment shim (33) to obtain the correct dimension between the head and the pump housing. It may be necessary to replace the shim with a new part.
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      Illustration 11	g02580532

   8. Install head assembly (26) and bolts (25).
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      Illustration 12	g00670626

   9. Use Tooling (D), Tooling (E), and Tooling (F) to check end play in shaft assembly (49). If end play exists in the shaft assembly, repeat Step 6 until the correct dimension between the head and the pump housing is reached.

   10. Remove bolts (25) and head assembly (26) from pump body (27). Remove bearing cone (32) and adjustment shim (33) from shaft assembly (49).

   11. Proceed with the assembly of the fan drive pump.
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   Illustration 13	g00670223

7. Install bearings (48).
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   Illustration 14	g00670207

8. Install spring (47).
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   Illustration 15	g00670206

9. Install swashplate (46).
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   Illustration 16	g00670205

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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.

   Note: There is a correct connection of the piston rod and the swashplate.

10. Install piston rod (45).
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    Illustration 17	g00670204

11. Install control piston (44).
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    Illustration 18	g00669745

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    Illustration 19	g00669744

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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.

    Note: There is spring force against retaining ring (43). When retaining ring (43) is not seated properly, the spring force will be released. Installation of the internal components in barrel (38) should be performed in a press. This is done to retain spring (42) and retaining ring (43).

12. Install pins (40), guide (41), and spring (42) in barrel assembly (38).

13. Use a suitable press and Tooling (A) to compress the spring (42) in barrel assembly (38).

14. Use Tooling (B) to install retaining ring (43). Install retaining ring (43).

15. Slowly release compression on spring (42). Make sure that the retaining ring (43) is seated properly.
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    Illustration 20	g00669743

16. Install retaining ball (39) on barrel assembly (38).
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    Illustration 21	g00669741

17. Install piston assemblies (37) in barrel assembly (38).
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    Illustration 22	g00669742

18. Install rotary group (36) onto the shaft. Make sure that the splines are aligned properly.
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    Illustration 23	g00669738

19. Install O-ring seal (34) on plug (35).
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    Illustration 24	g00669732

20. Install plug (34). Tighten plug (34) to a torque of 190 N·m (140 lb ft).
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    Illustration 25	g00669731

21. Install adjustment shim (33).
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    Illustration 26	g00669730

22. Install bearing cone (32) onto shaft assembly.
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    Illustration 27	g00669729

23. Install O-ring seal (31).
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    Illustration 28	g00669727

24. Install O-ring seal (28) and port plate (29) on head assembly (26).
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    Illustration 29	g02580532

25. Install head assembly (26) and bolts (25).
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    Illustration 30	g00670203

26. Install spool (23) in compensator valve (1). Install spacer (24) onto plug (22).

27. Apply Tooling (G) to the threads of plug (22). Install plug (22).
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    Illustration 31	g02581078

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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.

28. Install O-ring seal (17) to plug (16). Install guide (21), spring (20), spring (19), and plate (18) into compensator valve (1).

29. Install plug (16) into compensator valve (1).
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    Illustration 32	g00670198

30. Install spool (14) in compensator valve (1). Install spacer (15) on plug (13).

31. Apply Tooling (G) to the threads of plug (13). Install plug (13).
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    Illustration 33	g02581076

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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.

32. Install O-ring seal (8) to plug (7). Install guide (12), spring (11), spring (10), and plate (9) into compensator valve (1).

33. Install plug (7) into compensator valve (1).
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    Illustration 34	g00670191

34. Install O-ring seal (6) on plug (5).
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    Illustration 35	g00670190

35. Install plugs (5) in compensator valve (1).
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    Illustration 36	g00670188

36. Inspect O-ring seals (4) and replace the O-ring seals, if necessary. Install O-ring seals (4) on compensator valve (1).
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    Illustration 37	g00669721

37. Install bolts (2) and pressure and flow compensator valve (1) to piston pump (3).

End By:

1. Install the piston pump.