793C Off-Highway Truck Machine Systems Caterpillar

Assembly Procedure

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Illustration 1	g00463771

1. Use Tooling (B) to install retaining ring (55) in coupler assembly (54).
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   Illustration 2	g00463758

2. Install coupler assembly (54) in adapter assembly (49). Install dowels (53).
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   Illustration 3	g02717355

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   Illustration 4	g02703358

   Note: Do not lower the temperature of bearings (51).

3. Use Tooling (C) and a suitable press to install bearings (51) into pump body (48). The joint surfaces of bearings (51) must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward Outlet Port (U). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump body (48). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump body (48).

4. Install O-ring seal (52) in pump body (48).
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   Illustration 5	g02717371

5. Install bolt dampers (50A) into pump body (48) to a depth of 1.5 ± 0.50 mm (0.06 ± 0.020 inch).

6. Install bolt dampers (50B) into pump body (48) to a depth of 7.50 ± 0.50 mm (0.295 ± 0.020 inch).
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   Illustration 6	g00463748

7. Install pump body (48) on adapter assembly (49).
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   Illustration 7	g00463725

8. Install drive gear (46), idler gear (45), and O-ring seal (47) on pump body (48).
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   Illustration 8	g00463723

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   Illustration 9	g02703509

   Note: Do not lower the temperature of bearing (43).

9. Use Tooling (C) and a suitable press to install bearings (43) into pump body (40). The joint surfaces of the bearings must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward Outlet Port (V). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump body (40). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump body (40).

10. Install dowels (45) in pump body (40).

11. Install dowels (44) in body assembly (40).
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    Illustration 10	g00463721

12. Install pump body (40) on pump body (48). Install woodruff key (41) in drive gear shaft (42).
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    Illustration 11	g00463720

13. Install drive gear (38) and idler gear (39) in pump body (40).
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    Illustration 12	g00463719

14. Use Tooling (A) to install lip seal (37) in pump cover (32).
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    Illustration 13	g02717498

    Note: Do not lower the temperature of bearings (36).

15. Use Tooling (C) and a suitable press to install bearings (36) into pump cover (32). The joint surfaces of bearings (36) must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward Outlet Port (W). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump cover (32). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump cover (32).
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    Illustration 14	g02717507

16. Install O-ring seal (35) on pump cover (32).
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    Illustration 15	g00463715

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    Illustration 16	g00463716

    Note: Four bolts (31) contain thin washers (33) and thick washer (34).

17. Position washers (33) and washers (34) on bolts (31). Install pump cover (32) and bolts (31) with the washers into gear pump (3). Tighten bolts (31) to a torque of 47 ± 9 N·m (34.7 ± 6.6 lb ft).
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    Illustration 17	g00463714

18. Position gear pump (3) on a suitable surface. Install (30) and the washers. Tighten bolts (30) to a torque of 47 ± 9 N·m (34.7 ± 6.6 lb ft).

    Note: Gear pump (3) must turn freely after assembly.

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    Illustration 18	g02703636

    Note: Do not lower the temperature of bearings (29).

19. Use Tooling (C) and a suitable press to install bearings (29) into pump body (16). The joint surfaces of bearings (29) must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward Outlet Port (X). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump body (16). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump body (16).
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    Illustration 19	g02720234

    Note: Do not lower the temperature of bearings (26).

20. Use Tooling (C) and a suitable press to install bearings (26) into pump body (12). The joint surfaces of bearings (26) must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward the Outlet Port (Y). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump body (12). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump body (12).

21. Install O-ring seal (25) on pump body (12).
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    Illustration 20	g00463708

    Note: Idler gear (27) and drive gear (28) are identical. During installation, refer to the marks on each gear for the correct position.

22. Install drive gear (28) and idler gear (27) in pump body (16).
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    Illustration 21	g00463684

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    Illustration 22	g00463683

23. Install bolts (20) and the washers that hold flanges (22), cover (23), and seal (24) to pump body (12). Install O-ring seal (21) on pump body (12).
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    Illustration 23	g00463677

24. Install dowels (19) on spacer (15).
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    Illustration 24	g00463675

25. Install spacer (15) on pump body (12).
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    Illustration 25	g00463673

26. Install drive gear (13) and idler gear (14) in pump body (12). Install O-ring seal (17) on spacer (15). Install woodruff key (18) on drive gear (13).
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    Illustration 26	g02721675

27. Install pump body (12) and spacer (15) as a unit on pump body (16). Install O-ring seal (11) on pump body (12).
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    Illustration 27	g02720305

    Note: Do not lower the temperature of bearings (9).

28. Use Tooling (C) and a suitable press to install bearings (9) into pump cover (7). The joint surfaces of bearings (9) must be 30 ± 15 degrees from the centerline through the bearing bores. The joint surfaces must be toward Outlet Port (Z). Make sure that the bearings are 1.50 ± 0.25 mm (0.059 ± 0.010 inch) below the machined surface of pump cover (7). The bearing inside diameters must be 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) after installation. If, after three attempts the bearing diameters do not measure 31.798 ± 0.039 mm (1.2519 ± 0.0015 inch) replace pump cover (7).

29. Install two dowels (10) in pump cover (7).
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    Illustration 28	g00463670

30. Install dowels (8) on pump cover (7).
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    Illustration 29	g00463669

31. Install pump cover (7) and the O-ring seals. Refer to the marks for the correct position of bolts (6). Install bolts (6) and the washers that hold pump cover (7). Tighten bolts (6) to a torque of 47 ± 9 N·m (34.6 ± 6.6 lb ft).
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    Illustration 30	g00463667

    Note: Gear pump (2) must turn freely after assembly.

32. Install O-ring seals (4) and O-ring seal (5) on gear pump (2).
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    Illustration 31	g00463647

33. Connect gear pump (2) to gear pump (3). The weight of gear pump (2) is approximately 39 kg (86 lb). The weight of gear pump (3) is approximately 40 kg (88 lb).

34. Install bolts (1) and the washers that hold gear pump (2) and gear pump (3) together. Tighten bolts (1) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

35. The pump must rotate freely. Before the pump is activated, lubricate the pump with oil.

End By:

1. Install the gear pump. Refer to Disassembly and Assembly, "Gear Pump (Brake Release and Oil Cooling) - Install" for the correct procedure.