980L Tier 3 Wheel Loader Machine System Caterpillar

Assembly Procedure

Show/hide table

Illustration 1	g03687208

1. Use Tooling (C) to install shims (62) and bearing cups (61) into center section (3).
   Show/hide table

   Illustration 2	g03687131

2. Use Tooling (C) and a suitable press to install bearing cup (59). Install bearing cup (59).

3. Install bearings (58) into front pump housing (27).

   Note: There are two (2) Brass Pins (which are used to hold the bearings in place) in the front pump housing.

   Show/hide table

   Illustration 3	g03687122

4. Apply Tooling (E) to the outer diameter of lip seal (57). Use Tooling (C) and a suitable press to install lip seal (57) into retainer (55). Install lip seal (57)
   Show/hide table

   Illustration 4	g03687069

5. Install O-ring seal (56) onto retainer (55).
   Show/hide table

   Illustration 5	g03687012

6. Install retainer (55) and bolts (54) onto front pump housing (27). Tighten bolts (54) to a torque of 9.5 ± 0.2 N·m (84.1 ± 1.8 lb in).
   Show/hide table

   Illustration 6	g03688748

7. Install sleeves (53) into the swashplate.

8. Use the following procedure to determine the shim requirements needed between the retainers and the swashplate :
   Show/hide table

   Illustration 7	g03717223

   1. Install piston (52) and retaining ring (51) onto actuator (47).
      Show/hide table

      Illustration 8	g03717243

      Show/hide table

      Illustration 9	g03717210

      Show/hide table

      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.

   2. Use Tooling (D) and a suitable press to install retainer (50), spring (49), and retainer (48) onto actuator (47).
      Show/hide table

      Illustration 10	g03688741

   3. Install ring (42) onto shaft (43). Install shaft (43), actuator assembly (44), plate (45), and shims (46) onto swashplate (37).
      Show/hide table

      Illustration 11	g03688737

   4. Install pistons (40) into plate (41).
      Show/hide table

      Illustration 12	g03688733

      Show/hide table

      Illustration 13	g03688725

      Show/hide table

      Illustration 14	g03688714

   5. Install pistons (40) and plate (41) onto swashplate (37).

   6. Use a feeler gauge to measure the gap between retainer (38) and plate (41). Add shims (39) to achieve a clearance of 0.010 to 0.030 mm (0.0004 to 0.0012 inch).

   7. Apply Tooling (F) to bolts (36). Install shims (39), retainer (38), and bolts (36).

   8. Repeat Steps 8.f and 8.g for the remaining rotating group.
   Show/hide table

   Illustration 15	g03715525
   Front pump shaft assembly

   Show/hide table

   Illustration 16	g03718409
   Rear pump shaft assembly

9. Raise temperature of bearing cone (30) to 121 °C (250 °F). Install bearing cone (30) onto shaft assembly (29).

10. Apply Tooling (E) to the outer diameter of guide (31). Install guide (31) with the tapered edge facing away from bearing cone (30).

11. Use the following procedure to determine the end play for the shaft:
    Show/hide table

    Illustration 17	g03689822

    1. Install shaft assembly (29) into the housing.

    2. Raise the temperature of bearing (24) to 121 °C (250 °F). Install ring (25) and bearing (24) onto the shaft.
       Show/hide table

       Illustration 18	g03687208

    3. Install the shims (61) and bearing cups (60) into center section (3).
       Show/hide table

       Illustration 19	g03689827

    4. Install center section (3) and Tooling (G). Tighten Tooling (G) to a torque of 110 N·m (80 lb ft).
       Show/hide table

       Illustration 20	g00682185

    5. Use a rubber mallet to seat the shaft into the bearing cup.
       Show/hide table

       Illustration 21	g06131423

    6. Install a suitable bolt into the end of the shaft. Install Tooling (H), as shown. Use a lever to measure the amount of end play in the shaft. Add the appropriate thickness of shims to achieve an end play of 0.020 to 0.070 mm (0.0008 to 0.0028 inch).

       Note: The shims are located in the center section under the bearing cup.

    7. Remove the center section.
       Show/hide table

       Illustration 22	g03689822

    8. Remove shaft assembly (29) from the housing.

    9. Use Tooling (B) to remove ring (25) and bearing (24) from shaft (29).

    10. Repeat Steps 11.a through 11.i for the driven end of the pump.
    Show/hide table

    Illustration 23	g03738105

    Show/hide table

    Illustration 24	g06069965

    Show/hide table

    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 washers (34), spring (35), and inner and outer bushings (33) into barrel assembly (16).

13. Use a suitable press to compress spring (35).

14. Install retaining ring (32) into barrel assembly (16).

15. Repeat Steps 12 through 14 for the remaining barrel assembly.

16. Use the following procedure to determine the sliding block play:
    Show/hide table

    Illustration 25	g03718035

    1. Install the pins and bearings (58).

       Note: The pins must be installed to a depth below the bearings.

       Show/hide table

       Illustration 26	g03719080
       Dimension (A)

    2. Install the swashplate assembly into the pump housing.

    3. Use a depth gauge to level the swashplate assembly inside the pump housing. Take several measurements to make sure that the swashplate is level.

    4. Install a 5.0 mm (0.02 ft) ball bearing into each spherical hole on the swashplate assembly.

    5. Use the depth gauge to measure the distance from the face of the pump housing to the top of the ball bearings. This measurement will be referred to as Dimension (A).
       Show/hide table

       Illustration 27	g03717960
       Dimension (B)

    6. Measure the length of lubrication tubes (17). This measurement will be referred to as Dimension (B).
       Show/hide table

       Illustration 28	g03719155
       Dimension (C)

    7. Remove the shims from the holes in the head assembly. Use the depth gauge to measure the depth of the holes. This measurement will be referred to as Dimension (C).

    8. Use the following formula to determine the number of shims needed:

       A + C + 5 mm (0.19685 inch) = B + 0.01 to 0.15 mm (0.00039 to 0.00590 inch)

    Show/hide table

    Illustration 29	g03718031

17. Install pistons (40) into barrel assembly (16).
    Show/hide table

    Illustration 30	g03718034

18. Install shaft (29) into barrel assembly (16).
    Show/hide table

    Illustration 31	g06132601

    Show/hide table

    Illustration 32	g00669010

19. Install Tooling (J) on the shaft. Tooling (J) is used to prevent damage to the lip seal.

20. Raise the temperature of Tooling (J) to shrink into place.
    Show/hide table

    Illustration 33	g06075456

    Show/hide table

    Illustration 34	g06075460

21. Install spacer (25) and bearing cone (24).

22. Repeat Steps 16 through 21 for the other rotating group.
    Show/hide table

    Illustration 35	g06073901

23. Apply a paint mark on one drive shaft spline that aligns with the center of one of the kidney slots on the cylinder barrel.
    Show/hide table

    Illustration 36	g06073916

24. On the coupling, select any spline and apply a paint mark along the root of the spline. Apply a paint mark on each end of the coupling as well.
    Show/hide table

    Illustration 37	g06073923
    Use the rotating group for the rear pump for this step.

25. Install the coupling onto the drive shaft at various positions, until the paint mark on the coupling aligns between two kidney slots on the cylinder barrel.
    Show/hide table

    Illustration 38	g06073933

26. Slightly lift the Coupling, and then apply a paint mark on the drive shaft spline that aligns with the paint mark on the Coupling.
    Show/hide table

    Illustration 39	g06074244

27. The cylinder barrels for the front pump and rear pump must be properly “timed” to insure smooth, quiet operation of the pump. Illustration 39 shows how the two cylinder barrels are set in properly “timed” positions. Use the paint marks to ensure that the front pump and rear pump must be properly “timed” during final assembly.
    Show/hide table

    Illustration 40	g06075941

28. Install the O-ring seals and the back-up rings on lubrication tubes (20).
    Show/hide table

    Illustration 41	g06075970

29. Install lube tubes (20) and the shims determined in Step 16.h.
    Show/hide table

    Illustration 42	g06075990

30. Install port plate (21).
    Show/hide table

    Illustration 43	g06076008

31. Install rotating group (26) for the front pump onto center section (3).
    Show/hide table

    Illustration 44	g06076026

32. Make sure that both actuator pistons and lube tubes (20) are in the appropriate cavities on center section (3).
    Show/hide table

    Illustration 45	g06076039

33. Install front pump housing (27).
    Show/hide table

    Illustration 46	g03689827

34. With the pump still oriented as shown in Step 33, install Tooling (G). Do not clamp firmly - you only need to hold them together to reposition the pump. Reposition pump as shown.

35. Remove Tooling (G).
    Show/hide table

    Illustration 47	g06076158

36. Install coupling (22) onto the tail-splines of the front pump drive shaft. Orient the coupling so that the paint marks on the coupling and the drive shaft align with each other.
    Show/hide table

    Illustration 48	g03670277

    Note: Install the lubrication tubes and the shims determined in Step 16.h.

37. Install lube tubes (17) and the shims.

38. Install port plate (18) onto center section (3).
    Show/hide table

    Illustration 49	g03670005

39. Install rotating group (11) onto center section (3). Orient the rotating group so that the paint marks on the coupling and the drive shaft align with each other.
    Show/hide table

    Illustration 50	g06074722

40. Install connection rods (10).

41. Install new self-adhesive dampener strips to the connection rods marked (10A).
    Show/hide table

    Illustration 51	g03669361

42. Install bearing (8) and bearing cup (9) into rear pump housing (7).

    Note: There are two Brass Pins (which are used to hold the bearings in place) remaining in the front pump housing. If undamaged, leave the brass pins in the front pump housing.

    Show/hide table

    Illustration 52	g03669360

43. Use Tooling (A) and a suitable lifting device to install rear pump housing (7). Install rear pump housing (7).
    Show/hide table

    Illustration 53	g06128833

    Show/hide table

    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.

44. Install the O-ring seals and nuts (6). Tighten nuts (6) to a torque of 110 N·m (81 lb ft).

45. Apply Tooling (F) to bolts (4). Install bolts (4).
    Show/hide table

    Illustration 54	g06128816

46. Install the O-ring seals, valve group (2), the washers, and bolts (1) to center section (3).

End By:

1. Install the piston pump (implement).