TK711, TK721, TK722 and TK732 Track Feller Bunchers Machine Systems Caterpillar

Assembly Procedure

Note: If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information is available to analyze failures for piston pumps and motors. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".

Note: Inspect all parts. If any parts are worn or damaged use new parts for replacement. The installation of used parts during reconditioning is acceptable. Reuse and salvage information is available on piston pumps. Refer to Guideline For Reusable Parts and Salvage Operations, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure.

Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring seal may not have the same sealing properties as a new O-ring seal. Use Tooling (W) during the assembly procedure.

Note: Apply a light film of SAE 10 oil to all components before assembly.

Assembly Procedure for the Upper Pump Rotating Group

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Illustration 1	g01126386

1. Position gauge blocks from Tooling (N) on a surface plate in order to obtain Dimension (A) of 86.5 mm (3.41 inch).

2. Position Tooling (F) over the gauge blocks, and zero the indicator.
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   Illustration 2	g01125287
   Measurement that determines the thickness of shim (87) (87) Shim.

3. Slide the bearing assembly under Tooling (P).

4. The indicator should indicate between 0.00 mm (0.000 inch) and −0.10 mm (−0.004 inch) for the correct Dimension (A).
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   Table 2

   Table for Shim (87) (1)
   Shim	Thickness (mm)
   177-2513	6.2
   177-2514	6.3
   177-2515	6.4
   177-2516	6.5
   177-2517	6.6

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   (1)	Use the necessary shim (87) for adjusting Dimension (A) for the upper pump rotating group.

5. Add shims (87) in order to obtain the correct Dimension (A).

   Note: Use only one shim in order to obtain the stackup of the bearing assembly. The stackup of bearing assembly determines the position of the rotating group inside the main pump housing.

6. The following Steps 7 through 14 are for the buildup of bearing assembly (39).
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   Illustration 3	g01125106

7. Raise the temperature of bearing cone (93).

8. Install bearing cone (93) onto the shaft.
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   Illustration 4	g01117602

9. Install spacer (92).
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   Illustration 5	g01125108

10. Install bearing cup (91).
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    Illustration 6	g01125110

11. Install bearing spacer (90).
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    Illustration 7	g01125111

12. Raise the temperature of bearing cone (89).

13. Install bearing cone (89) on the shaft.
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    Illustration 8	g01125112

14. Install bearing cup (88) onto the shaft.
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    Illustration 9	g01125113

15. Install shim (87) onto the shaft.
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    Illustration 10	g01125114

16. Install bearing cup (86).
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    Illustration 11	g01125116

17. Raise the temperature of bearing cone (85).

18. Install bearing cone (85).
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    Illustration 12	g01117599

19. Install plate (84).
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    Illustration 13	g01117598

20. Use Tooling (G) in order to install retaining ring (83).

Assembly Procedure for the Lower Pump Rotating Group

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Illustration 14	g01126386

1. Position gauge blocks from Tooling (N) on a surface plate in order to obtain Dimension (A) of 86.5 mm (3.41 inch).

2. Position Tooling (P) over the gauge blocks, and zero the indicator.
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   Illustration 15	g01125119
   Measurement that determines the thickness of shim (76) (76) Shim.

3. Slide the bearing assembly under Tooling (P).

4. The indicator should indicate between 0.00 mm (0.000 inch) and −0.10 mm (−0.004 inch) for the correct Dimension (A).
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   Table 3

   Table for Shim (76) (1)
   Shim	Thickness (mm)
   177-2487	3.3
   177-2488	3.4
   177-2489	3.5

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   (1)	Use the necessary shim (76) for adjusting Dimension (A) for the lower pump rotating group.

5. Add shims (76) in order to obtain the correct Dimension (A).

   Note: Use only one shim in order to obtain the stackup of bearing assembly. The stackup of the bearing assembly determines the position of the rotating group inside the main pump housing.

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   Illustration 16	g01125120

6. Raise the temperature of bearing cone (82).

7. Install bearing cone (82).
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   Illustration 17	g01125121

8. Install spacer (81).
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   Illustration 18	g01125122

9. Install bearing cup (80).
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   Illustration 19	g01125125

10. Install spacer (79).
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    Illustration 20	g01125126

11. Raise the temperature of bearing cone (77).

12. Install bearing cone (77).
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    Illustration 21	g01125128

13. Install bearing cup (78).
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    Illustration 22	g01125130

14. Install shim (76).
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    Illustration 23	g01125132

15. Install bearing cup (75).
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    Illustration 24	g01125133

16. Raise the temperature of bearing cone (74).

17. Install bearing cone (74).
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    Illustration 25	g01117592

18. Install plates (73).
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    Illustration 26	g01117591

19. Use Tooling (G) in order to install retaining ring (72).

Setting the Bearing Preload

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Illustration 27	g01125134
Upper Pump Rotating Group (B) Dimension that is determined by spacer (50). (84) Plates that determine bearing preload.

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Illustration 28	g01125447
Lower Pump Rotating Group (B) Dimension that is determined by spacer (50). (73) Plates that determine bearing preload.

1. After the pump rotating groups have been assembled you must perform two primary procedures. Complete the following procedures: Bearing preload and Lift-off Limitation.

   Note: The bearing preload procedure that follows pertains only to new bearings that have the original lubricant.

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   Illustration 29	g00682451

   Note: Setting the bearing preload of the rotating group will require the use of bearing Support (K).

2. To fabricate bearing support (K), cut a 90 degree vee approximately 150 mm (5.9 inch) wide into a block of wood. Call this Dimension (C).

3. This wood block will be used to hold the rotating group while the drive shaft is rotated.

4. The following plates are used to adjust the bearing preload.
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   Table 4

   Table for Plate (73) and (84) (1)
   Plate	Thickness (mm)
   177-2491	2.6
   177-2492	2.65
   177-2493	2.70
   177-2494	2.75
   177-2495	2.80
   177-2496	2.85
   177-2497	2.90
   177-2498	2.95

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   (1)	Use the necessary plates (73) and (84) for adjusting the bearing preload on both rotating groups.

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   Illustration 30	g00681982

5. Place the upper rotating group onto bearing Support (K).

6. In order to check bearing preload, install Tooling (T) into the center of the upper rotating pump group with a dial type torque wrench.

   Rolling torque ... 3.75 ± 0.25 N·m (33 ± 2 lb in)

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   Illustration 31	g00682002

7. Place the lower rotating group onto bearing Support (K).

8. In order to check bearing preload, install Tooling (U) into the center of the upper rotating pump group with a dial type torque wrench.

   Rolling torque ... 3.75 ± 0.25 N·m (33 ± 2 lb in)

Adjustment for Lift-Off Limitation (Cylinder Barrel To Port Plate for Maximum Separation)

Reference: Refer to Tool Operating Manual, NEHS0699-01 for completing this procedure.

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Illustration 32	g00526328

1. Raise the temperature of the main pump housing. Install the upper pump rotating group and the lower pump rotating group in both of the pump rotating group's original locations in the main pump housing.

2. Make sure that the timing marks on each pump rotating group are in alignment with each other, as shown.
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   Illustration 33	g01125141

3. Install both retaining plates (54) and centering pins (55).
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   Illustration 34	g01125142

4. Tighten socket head screws (53) that hold the retaining plates and the centering pins.
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   Illustration 35	g00682512

5. Install three lead balls into Tooling (R), as shown.

6. Make sure that the lead ball is inserted into the large holes on the gauge plate. To keep the lead balls from falling out of the gauge plate during installation, press on each lead ball with your thumb.

   Note: Do not crush the lead balls. Pressing the balls too deeply into the gauge plate will provide inaccurate measurements.

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   Illustration 36	g01125145

7. Place Tooling (R) and the three lead balls on the centering pins (55).
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   Illustration 37	g01125146

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   Illustration 38	g01125154

8. Carefully place barrels (49) over Tooling (R) and centering pins (55).

   Note: Do not drop the cylinder barrel onto the centering pin. Dropping the cylinder barrel will prematurely crush the lead balls. This will cause inaccurate measurements.

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   Illustration 39	g01123690

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   Illustration 40	g01123692

9. Install pin (46) into piston (45).

10. Install set screw (44) into piston (45).
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    Illustration 41	g01123682

11. Install piston (43).
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    Illustration 42	g01123681

12. Install bolts (42).
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    Illustration 43	g01123679

13. Install O-ring seals (38), O-ring seals (40), spring retainers (41), and springs (39).
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    Illustration 44	g01123678

14. Install spring retainers (37) and springs (36).
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    Illustration 45	g01123677

15. Install spring retainer (34), spring (33), spring retainer (32), and O-ring seal (35).
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    Illustration 46	g01123676

16. Install spring (31).
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    Illustration 47	g01123863

17. Install nut (29), screw (28), and backup ring (30).
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    Illustration 48	g01123675

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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 cap (27) and valve (26).

19. Repeat Steps 15 through Steps 18 for the opposite valve.
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    Illustration 49	g01123667

20. Install O-ring seals (24) and bushings (25).
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    Illustration 50	g01123665

21. Install springs (23).
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    Illustration 51	g01123664

22. Install spring retainers (22).
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    Illustration 52	g01123663

23. Install valves (21) and valves (20).
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    Illustration 53	g01123662

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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.

24. Install control housing (17) and bolts (19).
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    Illustration 54	g01123661

25. Install spring retainers (18) into control housing (16).
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    Illustration 55	g01123660

26. Install control housing (17), control housing (16), and bolts (15) evenly.
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    Illustration 56	g01125155
    (S) Suction side

27. Apply petroleum jelly under both port plates (48) prior to installation.

28. Place each port plates (48) into position on the pump control, as shown.
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    Illustration 57	g01125156

29. Install gasket (52) on the main pump housing.
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    Illustration 58	g01125157

30. Fasten Tooling (B) and a suitable lifting device to head assembly (6).

31. Carefully install head assembly (6) on top of the main pump housing.

    Note: If the pump control comes down hard onto the port plates, you should remove the pump control. Then, verify that you have not damaged the lead balls. If the lead balls are damaged, you should replace the lead balls. Then, reinstall the pump control.

32. Torque bolts (5) to 240 ± 40 N·m (175 ± 30 lb ft), while you turn the pump shaft.
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    Illustration 59	g01125157

33. Remove bolts (5).

34. Use Tooling (B) and a suitable lifting device in order to remove head assembly (6).
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    Illustration 60	g01125154

35. Remove barrels (49).

36. Remove Tooling (R).

37. Determine the lift-off Dimension, as follows.
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    Illustration 61	g01125159

38. Measure all three lead balls and write down the average of the three. Call this Dimension (Z).

    Note: Keep each Tooling (R) with the respective rotating groups because you will have different lift-off Dimensions for each rotating group.

39. Use the following equation to determine the Lift-Off Limitation:

    (Z) - 0.40 ± 0.10 mm (0.016 ± 0.004 inch)

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    NOTICE
    Do not interchange the spacers. Interchanging the spacers can result in pump damage that cannot be repaired.

40. Dimension (B) should equal the thickness of one of the spacers (8).
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    Table 5

    Table for Spacer (50) (1)
    Spacer	Thickness (mm)
    177-2509	12.3
    177-2508	12.4
    177-2507	12.5
    177-2506	12.6
    177-2505	12.7
    177-2504	12.8

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    (1)	Use the necessary spacer (50) for setting the lift-off limitation for the upper pump rotating group and the lower pump rotating group.

    Reference: Refer to Illustrations 27 and 28 for Dimension (B).

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    Illustration 62	g01125142

41. Remove socket head screws (53) that hold the retaining plate and the centering pin.
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    Illustration 63	g01125141

42. Remove both retaining plates (54) and centering pins (55).

43. Turn the main housing over 180 degrees.
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    Illustration 64	g01117571

44. Install plug (58).
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    Illustration 65	g01125160

45. Install bearing (71) in the bearing's original position in the main pump housing. The bearing is a slip fit.
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    Illustration 66	g01125161

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    Illustration 67	g01125162

46. Use a hammer in order to install key (69) into shaft (68).

47. Raise the temperature of gear (70).

48. Lower the temperature of shaft (68).

49. Place gear (70) in the main pump housing above bearing (71).

50. Install the cooled shaft through gear (70) and into bearing (71).

    Note: Make sure that you align the key in shaft (68) with the corresponding slot in gear (70).

51. Install bearing (67) on the shaft. Bearing (67) is a slip fit on the shaft.
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    Illustration 68	g01117580

52. Assemble the pilot pump. Refer to Disassembly and Assembly, "Gear Pump (Pilot Pump) - Assemble".

53. Install O-ring seals (66) to the pilot pump.
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    Illustration 69	g01117577

54. Place pilot pump (64) in position in the main pump housing.

55. Install bolts (65) that hold the pilot pump in position.
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    Illustration 70	g01125163

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    Illustration 71	g01125164

56. Position lip seal (63) inside the main pump housing.

    Note: Use Tooling (S) to install the lip seal (63) into the bore of the main housing. Drive the seal slightly past the retaining ring groove in the main pump housing.

57. Make sure that the sealing lip is facing toward the inside of the main pump housing.
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    Illustration 72	g01117574

58. Install shim (62).
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    Illustration 73	g01117573

59. Use Tooling (D) and install retaining ring (61).

60. Turn the main pump housing over 180 degrees.
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    Illustration 74	g01117568

61. Install two rings (57) on each pistons (56).
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    Illustration 75	g01117567

62. Install pistons (56) in the piston's original locations in the pump rotating groups.
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    Illustration 76	g01117565

63. Install retaining plates (54) and centering pins (55) in the original positions over the pistons. Make sure that the screw holes in the retaining plates are in alignment with the screw holes in the pump rotating groups.
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    Illustration 77	g01117564

64. Apply Tooling (V) on the threads of socket head screws (53).

65. Install the socket head screws in order to hold retaining plates (54) to the pump rotating groups. Tighten the socket head screws evenly.

66. Install gasket (52).
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    Illustration 78	g01117563

67. Apply petroleum jelly to bevel spring washers (51) and spacer (50) in order to prevent bevel spring washers (51) and spacer (50) from falling out of barrel (49) during installation.
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    Illustration 79	g01125165
    (49) Cylinder barrel. (50) Spacer. (51) Bevel washers.

    Note: Bevel spring washers (51) are not flat. These washers should be installed so that the washers provide the maximum amount of height.

68. Install spacers (50) and four bevel spring washers (51) in each barrels (49), as shown.

    Note: Use the spacer that was determined in Steps 1 through 41.

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    Illustration 80	g01117562

69. Install barrels (49) in the cylinder barrel's original locations on the pump rotating groups.
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    Illustration 81	g01125166

70. Install dowels (47) in the main pump housing.
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    Illustration 82	g01125155
    (S) Suction side

71. Apply petroleum jelly under both port plates (48) prior to installation.

72. Place each port plates (48) into position on the head assembly, as shown.
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    Illustration 83	g01125157

73. Fasten Tooling (B) and a suitable lifting device to head assembly (6), as shown. Place the head assembly in position on the main hydraulic pump.

74. Install bolts (5) that hold the head assembly to the main hydraulic pump.

75. Torque bolts (5) to 240 ± 40 N·m (175 ± 30 lb ft), while you turn the pump shaft.

76. Install the drain plug.
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    Illustration 84	g01123653

77. Install tube assembly (4).
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    Illustration 85	g01123648

78. Install manifold (3) and bolts (2).
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    Illustration 86	g01123647

79. Install drain plug (1).

80. Remove the main hydraulic pump from Tooling (A).

End By:

1. Install the main hydraulic pump. Refer to Disassembly and Assembly, "Piston Pump (Main Hydraulic) - Install".

2. Install the saw pump. Refer to Disassembly and Assembly, "Piston Pump (Saw) - Install".