988K XE Wheel Loader Machine Systems Caterpillar

Assembly Procedure

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Illustration 1	g03440537

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Illustration 2	g03440473

1. Use Tooling (A) to install seal (33) in pump housing (6). Install the seal until the seal is just below the face of the housing. Do not seat seal (33) now.

2. Install O-ring seal (34).
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   Illustration 3	g03440457

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   Illustration 4	g03440537

3. Install retaining ring (32).

4. Use Tooling (A) and a suitable press to install retaining ring (32) and the seal into pump housing (6). Press retaining ring (32) and the seal until retaining ring (32) is installed in the groove in pump housing (6).
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   Illustration 5	g03440416

5. Install shaft (11) and bearing cone (30) in pump housing (6).
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   Illustration 6	g03440389

6. Install bearings (30) and spring (31).

7. Apply Tooling (C) to screws (29). Install screws (29). Tighten screws (29) to a torque of 5 ± 1 N·m (45 ± 10 lb in).
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   Illustration 7	g03440385

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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: Caution must be used when you install the plate. Do not dislodge the spring.

8. Install swashplate (26) in pump housing (6) with socket (28) facing toward the spring.
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   Illustration 8	g03440381

9. Install rod (27) in the bore and engage rod (27) in the socket on swashplate (26).

   Note: Swashplate (26) will need to be angled to connect rod (27) to swashplate (28). Note that there is a correct connection of the piston rod and the swashplate.

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   Illustration 9	g03440380

10. Install piston (25) in the bore of pump housing (6).
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    Illustration 10	g03440379

11. Install plug (24) and the O-ring seal. Tighten plug (24) to a torque of 190 N·m (140 lb ft).
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    Illustration 11	g03440278

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    Illustration 12	g03440244

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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.

12. Install pressure pins (23), retaining disc (22), and spring (21) in barrel (18).

13. Install retaining ring (20) on top of spring (21). Use Tooling (A) and a suitable press to compress spring (21). Compress until retaining ring (20) can be installed in the groove in barrel (18).
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    Illustration 13	g03440242

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    Illustration 14	g03440240

14. Install retaining ball (19). Install retaining plate (16) with pistons (17) in barrel (18).

    Note: Set bearing preload before you install the rotating group. The bearing preload should be 0.00 to 0.05 mm (0.000 to 0.002 inch).

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    Illustration 15	g03440833

15. Do not install shim (14). Install bearing cone (12) onto shaft (11). Assemble the pump without shim (14) to check the preload of the bearing cone.
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    Illustration 16	g06261366

16. Install port block (8) and bolts (7) on pump housing (6). Tighten bolts (7) to a torque of 165 N·m (122 lb ft).
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    Illustration 17	g03441136

17. Install Tooling (B) onto pump housing (6). Use the dial indicator to determine the end play of shaft (11).

18. Be sure that you move shaft (11) completely in both directions. Use appropriate tools to move shaft (11).

19. The thickness of shim (14) (not shown) should equal the end play measurement plus 0.05 mm (0.002 inch). For example, if the end play is 2.16 mm (0.085 inch) then the shim thickness should be 2.21 mm (0.087 inch).

20. Record the measurement.

21. If necessary, grind or replace the shim to meet the determined measurement.
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    Illustration 18	g06261366

22. Remove bolts (7), port block (8), and the bearing cone from pump housing (6).
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    Illustration 19	g03441277

    Note: All parts must be in the proper position.

23. Wrap the pistons (17) with string but do not tie the string. Hold the string tight and carefully install rotating group (15) in housing (6). The splines on shaft (11) must engage with splines in retaining ball (19).
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    Illustration 20	g03440157

24. Install shim (14) onto shaft (11).
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    Illustration 21	g03440156

25. Install bearing cone (12) on shaft (11). Install O-ring seals (13).
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    Illustration 22	g03440139

26. Install O-ring seal (9) and port plate (10) to the port block (8).
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    Illustration 23	g06261366

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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.

27. Install port block (8) and bolts (7) on pump housing (6). Tighten bolts (7) to a torque of 165 N·m (122 lb ft).
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    Illustration 24	g06261365

28. Install solenoid (4) and nut (5) onto compensator valve (2).
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    Illustration 25	g06261363

29. Install compensator valve (2) bolts (1), gasket (3), and the O-ring seals. Tighten bolts (1) to a torque of 15.5 ± 1.5 N·m (137.18 ± 13.28 lb in).

End By:

1. Install the piston pump (Hydraulic Fan).