826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Machine Systems Caterpillar

Assembly Procedure

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Illustration 1	g02674083

1. Use the proper equipment to handle bearing cone (32). Raise the temperature of bearing cone (32). Install bearing cone (32) onto the shaft assembly (27).
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   Illustration 2	g02673122

2. Use the proper equipment to handle the bearing cup. Lower the temperature of bearing cup (31) and install bearing cup (31) in pump body (5).
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   Illustration 3	g02673116

3. Inspect the O-ring seals on plugs (30). Replace the O-ring seals, if necessary. Install plugs (30) in pump body (5).
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   Illustration 4	g02673076

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   Illustration 5	g00670302

4. Install retaining ring (28). Use Tooling (A) to install seal (29) (not shown).
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   Illustration 6	g02673056

5. Install shaft assembly (27).

6. Use the following steps to determine the proper preload on the bearings of the pump assembly.
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   Illustration 7	g02672881

   1. Use the proper equipment to handle the bearing cup. Lower the temperature of bearing cup (8) and install the bearing cup in head assembly (4).
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      Illustration 8	g02674239
      Typical Example

   2. Install adjustment shim (11) and bearing cone (10) onto shaft assembly (27).
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      Illustration 9	g02674307

   3. Position head assembly (4) onto pump body (5).
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      Illustration 10	g01140689

   4. Use Tooling (G) 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 (11) in order 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	g02674476

   8. Install bolts (3) in head assembly (4) and pump body (5). Tighten bolts (3) to a torque of 58 N·m (43 lb ft).
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      Illustration 12	g02674498

   9. Use Tooling (D), Tooling (E), and Tooling (F) to check end play in shaft (27). 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 (3) and head assembly (4) from pump body (5). Remove bearing cone (10) and adjustment shim (11) from shaft assembly (27).

   11. Proceed with the assembly of the fan drive pump.
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   Illustration 13	g02673044

7. Install bearings (26).
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   Illustration 14	g02673039

8. Install spring (25).
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   Illustration 15	g02673016

9. Install swashplate (24).
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   Illustration 16	g02672983

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

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

10. Install piston rod (23).
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    Illustration 17	g02672980

11. Install control piston (22).
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    Illustration 18	g02672956

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    Illustration 19	g02672924

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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 (21). When retaining ring (21) is not seated properly, the spring force will be released. Installation of the internal components in barrel (16) should be performed in a press. This is done in order to retain spring (20) and retaining ring (21).

12. Install pins (18), guide (19), and spring (20) in barrel assembly (16).

13. Use a suitable press and Tooling (A) to compress the spring (20) in barrel assembly (16).

14. Use Tooling (B) to install retaining ring (21).

15. Slowly release compression on spring (20). Make sure that retaining ring (21) is seated properly.
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    Illustration 20	g02672921

16. Install retaining ball (17) on barrel assembly (16).
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    Illustration 21	g02672917

17. Install piston assemblies (15) in barrel assembly (16).
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    Illustration 22	g02672912

18. Install rotary group (14) onto the shaft. Make sure that the splines are aligned properly.
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    Illustration 23	g02672909

19. Install O-ring seal (13) on plug (12).
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    Illustration 24	g02672906

20. Install plug (12).
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    Illustration 25	g02672902

21. Install the adjustment shim (11).
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    Illustration 26	g02672900

22. Install bearing cone (10) on the shaft.
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    Illustration 27	g02672896

23. Install O-ring seal (9).
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    Illustration 28	g02672800

24. Install O-ring seal (6) and port plate (7) on head assembly (4).
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    Illustration 29	g02672576

25. Install head assembly (4) and bolts (3) onto pump body (5). Tighten bolts (25) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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    Illustration 30	g02672457

26. Install bolts (1), valve group (2), and the gasket onto the piston pump. Tighten bolts (1) to a torque of 34 ± 3 N·m (25 ± 2 lb ft).

End By:

1. Install the (Pilot, Brake) piston pump.