D350E Series II Articulated Truck Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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

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Illustration 1	g00659408

1. Use Tooling (B) to install retaining ring (61) in pump housing (1).
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   Illustration 2	g00659410

2. Use Tooling (A) to install seal (62) in pump housing (1).
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   Illustration 3	g00663434

3. Lower temperature of bearing cup (63) and install the bearing in pump housing (1).
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   Illustration 4	g00659407

4. Install swashplate bearings (60) in pump housing assembly (1).
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   Illustration 5	g00659406

   Note: Apply light grease to the inside of the barrel. The grease will retain the pins during assembly of the barrel.

5. Install pins (57), spacer (58), spring (59) and retaining ring (56) in barrel (55).
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   Illustration 6	g00659400

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   Illustration 7	g00659398

6. Use Tooling (A) and Tooling (C) to compress, and install the hidden spring and retaining ring (56) in barrel assembly (55).
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   Illustration 8	g00661130

7. Position barrel (55) on blocks, as shown. Install bearing (54) on barrel assembly (55).
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   Illustration 9	g00659396

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   Illustration 10	g00659395

8. Install piston assemblies (53) in plate (52).
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   Illustration 11	g00659394

9. Install plate assembly (52) on the rotating group.
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   Illustration 12	g00659393

10. Install swashplate (51) on the rotating group.
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    Illustration 13	g00659392

11. Raise the temperature of bearing (50) to 135 °C (275 °F). Install bearing cone (50) on shaft (49).
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    Illustration 14	g00663445

12. Use the following steps to determine the proper preload on the bearings of the pump assembly.

    1. Install shaft assembly (49) in pump housing (1).
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       Illustration 15	g00663454

    2. Install adjustment disc (47) and bearing (46) on shaft assembly (49).
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       Illustration 16	g00663457

    3. Lower the temperature of bearing cup (41) and install the bearing cup in head (32).
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       Illustration 17	g00663459
       Typical Example

    4. Position head (32) on pump housing (1).

    5. Use Tooling (C) to measure the distance between the head and the pump housing.

    6. Take measurements at three equal intervals on the surface between the head and the pump housing.

    7. The average of the three dimensions should be zero to 0.05 mm (0.0020 inch).

    8. Adjustment disc (47) must be replaced or ground to this dimension.
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       Illustration 18	g00659362

    9. Install bolts (31) in head (32) and the pump housing. Tighten to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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       Illustration 19	g00599565
       Typical Example

    10. Use Tooling (D), (E), and (F) to check for end play in shaft (49). If end play exists in the shaft assembly, repeat Step 12 until the correct dimension is reached.

    11. Remove bolts (31) and head assembly (32) from the pump housing. Remove bearing (46) and adjustment disc (47) from shaft (49). Remove the shaft from the pump housing.

    12. Proceed with the assembly of the pump housing assembly.
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    Illustration 20	g00659390

13. Install shaft assembly (49) in rotating group (48).
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    Illustration 21	g00659387

14. Position the rotating group upright. Install the entire rotating group (48) in pump housing assembly (1).
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    Illustration 22	g00659386

15. Install adjustment spacer (47) on the shaft and on pump housing assembly (1).
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    Illustration 23	g00659383

16. If necessary, raise the temperature of bearing cone (46) to 135 °C (275 °F). Install the bearing cone on the shaft in the pump housing assembly. Install O-ring seal (45) in pump housing assembly (1).
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    Illustration 24	g00659381

17. Install spring (44) in plunger (42).
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    Illustration 25	g00659376

18. Install plunger assembly (42) and guide (43) in pump housing assembly (1).
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    Illustration 26	g00663457

19. Lower the temperature of bearing cup (41). Install bearing cup (41) in head assembly (32).
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    Illustration 27	g00659374

20. Install cylinder (39) and piston (40) in head assembly (32).
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    Illustration 28	g00659370

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    Illustration 29	g00659365

21. Install adjuster screw (38), locknut (37), seal (36), and cap (35) in head assembly (32).
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    Illustration 30	g00659364

22. Install O-ring seals (33) in head assembly (32). Install a light coat of grease on plate (34). Install the plate on head assembly (32).
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    Illustration 31	g00659363

23. Carefully install head assembly (32) on pump housing (1).
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    Illustration 32	g00659362

24. Install bolts (31) in head assembly (32) and in pump housing (1). Tighten the bolts to a torque of 85 N·m (63 lb ft).
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    Illustration 33	g00659358

25. Install seal (30) on orifice (29). Install the orifice in valve (3).
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    Illustration 34	g00659354

26. Assemble plug (17), as follows:

    1. Install adjuster screw (26), seal (24), and nut (25) on plug (17).

    2. Install seal (27) and cap (28) on adjuster screw (26).

    3. Install O-ring seal (23) on plug (17).
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    Illustration 35	g00659353

27. Install stem (18), spring retainer (19), springs (20) and (21), and seat (22) in valve (3). Install plug (17) in the valve.
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    Illustration 36	g00659351

28. Assemble plug (5), as follows:

    1. Install seal (10) and seat (11) in plug (5).

    2. Install adjuster screw (14), seal (12), and nut (13) on plug (5).

    3. Install seal (15) and cap (16) on adjuster screw (14).
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    Illustration 37	g00659350

29. Install stem (6), spring retainer (7), springs (8) and (9), and plug (5) in valve (3 ).
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    Illustration 38	g00659347

30. Install O-ring seals (4) in valve (3).
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    Illustration 39	g00659341

31. Install valve (3) and bolts (2) in pump housing (1).

End By:

1. Install the pump. Refer to Disassembly and Assembly, "Pump Group Piston (Brake ) - Install".