963C Track-Type Loader Power Train Hydraulic Drive Pump - Assemble Caterpillar

Assembly Procedure

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Regular maintenance and frequent inspections are routine precautions. Practice preventive maintenance before damage occurs. Preventive maintenance can help to avoid a failure. If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information is available to analyze failures of the piston pump and the motor. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor Failures".

Note: Many times, the installation of new parts is not necessary. The installation of used parts during reconditioning is acceptable. Used parts can result in a substantial cost reduction. Information is available on reusing the piston pumps and the motors. Refer to Guideline For Reusable Parts, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might have caused the original failure.

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. Dirt and other contaminants can damage the precision components of the pump or of the motor. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.

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Illustration 1	g00582656

1. Install retainer (78).
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   Illustration 2	g00582652

2. Install springs (77) and (76).
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   Illustration 3	g00582628

3. Install retainer (75).
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   Illustration 4	g00582622

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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.

4. Use a suitable press and Tooling (G) to compress the spring. Install spacer (74). Slowly release the pressure on the spring.
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   Illustration 5	g00582619

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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.

5. Use a suitable press to compress the spring. Use Tooling (F) in order to install retaining ring (73). Repeat Steps 1 through 5 for the other side of the valve.
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   Illustration 6	g00794223

6. Install ring (70) and (71) on each side. Install O-ring seal (72).
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   Illustration 7	g00794221

7. Install O-ring seal (69).
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   Illustration 8	g00794220

8. Screw the cover onto the valve. Install nut (68).
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   Illustration 9	g00582504

9. Install O-ring seal (67) on the cover.
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   Illustration 10	g00582495

10. Install cover (66). Install bolts (65).
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    Illustration 11	g00582491

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    Illustration 12	g00582463

11. Install cover (63) with valve assembly (64). Install bolts (62).
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    Illustration 13	g00582451

12. Install bearing cradles (59). Install retainers (60).

    Note: The following components must be assembled in a vertical position: bearing cradles, swashplate assembly, shaft assembly and barrel assembly.

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    Illustration 14	g00999854

13. Install rods (57) on the swashplate. Install bearings (58) over the rods on the swashplate. Install plate (56) on the swashplate.

    Note: Apply a light coat of petroleum jelly to the bearings for installation purpose.

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    Illustration 15	g00581942

14. Install swashplate assembly (55). The swashplate assembly must stay together while the swashplate is being installed into the housing.
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    Illustration 16	g00582457

15. Install the O-ring seals on plugs (61). Install plugs (61) in the housing.

    Note: Use a small screwdriver in order to turn retainers (60). Swashplate assembly (55) must move. This will ensure that rods (57) are in slotted retainers (60).

16. Raise the temperature of bearing (54). Use a suitable press in order to install shaft assembly (52) through bearing (54).

    Note: Lubricate the bearing with the lubricant that is being used.

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    Illustration 17	g00581928

17. Use Tooling (E) in order to install retaining ring (53).
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    Illustration 18	g00999855

    Note: Install Tooling (L) over shaft assembly (52) in order to protect the seal during installation.

    Note: Install the shaft assembly into the pump housing in a vertical position.

18. Lower the housing of the axial piston pump into position over shaft assembly (52). Do not disrupt the location of swashplate assembly (55) during the shaft installation.

19. The following procedure is used to determine the correct shim thickness for the lift off adjustment:
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    Illustration 19	g00585935

    1. Place port plate (17) onto a surface plate. The flat side of the port plate should rest on the surface plate.
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       Illustration 20	g01002244

    2. Place Tooling (H) on the inside diameter of port plate (17). The chamfered side faces upward.
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       Illustration 21	g00585961

    3. Install barrel assembly (41) onto Tooling (H) and port plate (17).
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       Illustration 22	g01002247

    4. Install Tooling (I) on top of the barrel assembly, as shown.
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       Illustration 23	g00585975

    5. Make sure that all the springs and shims have been removed from spring retainer (43). Install the spring retainer (43) over Tooling (I).
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       Illustration 24	g00585985

    6. Install plate (42) onto the retainer, as shown.
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       Illustration 25	g01002249

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       Illustration 26	g00586012

    7. Bolt Tooling (J) and Tooling (K) together. Place the Tooling on top of the plate, as shown.
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       Illustration 27	g00586047

    8. Use a Vernier scale for measuring height or a similar tool in order to measure the dimension in Step 19.i.
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       Illustration 28	g00586062

    9. Measure the distance from the top of the surface plate to the top of Tooling (J). Record this dimension as Dimension (X).

       Note: The following calculations are used to determine the shim thickness and the height of the lift off limitation. Dimension (X) - Dimension (W) = Dimension (Y) Dimension (Y) is the Lift Off Limitation Height without the shim. The correct Lift Off Limitation Height of the pump is 117.4 mm +0.0, -0.2 inch. Call this height Dimension (Z). Dimension (Z) - Dimension (Y) = Thickness of the shim to be used to obtain the correct Lift Off Limitation Height.

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    Illustration 29	g00581786

20. Install washer (47), spring (48), and washer (47) into the barrel assembly.
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    Illustration 30	g00581784

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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.

21. Use Tooling (B) and a suitable press in order to install retaining ring (46).
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    Illustration 31	g00581780

22. Install springs (45) in the correct sequence. Install shim (44) on top of the springs. Refer to Step 19.i.
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    Illustration 32	g00581773

23. Install spring retainer (43).
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    Illustration 33	g00581740

24. Install pistons and plate (42) in the original location in the barrel assembly.
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    Illustration 34	g00681514

25. Wrap a piece of nylon string around the pistons, as shown.
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    Illustration 35	g00775264

26. Install barrel assembly (41) into the pump housing. Use the nylon string in order to hold the assembly together during installation. Do not allow the swashplate assembly to fall apart while barrel assembly (41) is being installed. Remove the nylon string.
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    Illustration 36	g00581282

27. Install O-ring seal (38). Install O-ring seal (39). Install O-ring seals (40).
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    Illustration 37	g00581281

28. Install O-ring seals (37).
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    Illustration 38	g00581276

29. Install valve assembly (36). Install bolts (34). Install gasket (35).
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    Illustration 39	g00581264

30. Install cover (33). Install bolts (32).
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    Illustration 40	g00581225

31. Install valve (31). Install O-ring seal (30).
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    Illustration 41	g00581224

32. Install cover assembly (29). Install bolts (28). Repeat for the other side.
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    Illustration 42	g00581200

33. Assemble both valves, as follows: O-ring seal (24), backup ring (25) and O-ring seal (26).
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    Illustration 43	g00581207

34. Install valve (27) into the head. Tighten valve (27) to a torque of 100 ± 2 N·m (74 ± 2 lb ft).
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    Illustration 44	g00722813

35. Install valve (23) into the head. Tighten valve (23) to a torque of 100 ± 2 N·m (74 ± 2 lb ft).
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    Illustration 45	g00999085

36. Install O-ring seals (22) to plugs (21), (20), and (19).
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    Illustration 46	g00999084

37. Install plug assemblies (21), (20), and (19) to the head.
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    Illustration 47	g00581027

38. Use Tooling (A) to install bushing (16). Install the bushing and orient the groove into the original location by using the previous marks.
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    Illustration 48	g00581022

39. Use Tooling (A) to install bushing (15).
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    Illustration 49	g00794209

    Note: The notch in the port plate must face the two valves on the head assembly.

40. Install port plate (17) and bearing (18), if necessary.
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    Illustration 50	g00775369

41. Install O-ring seals (13). Install O-ring seal (14).
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    Illustration 51	g00581009

42. Install head assembly (12). Install bolts (11).
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    Illustration 52	g00581004

43. Install key (10). Install retaining ring (9) onto the shaft.
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    Illustration 53	g00580995

44. Install shaft (7). Install O-ring seal (8).
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    Illustration 54	g00580969

45. Install plate (6) in the original position.
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    Illustration 55	g00580966

46. Install bushing (5) in the original location.
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    Illustration 56	g00716074

    Note: Gear set (4) with the larger diameter has a chamfered edge. This edge goes toward charge pump (2).

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    Illustration 57	g00717200

47. Install gear set (4) in the original location. Install O-ring seal (3) in charge pump (2).

    Note: Crescent (M) in the charge pump must face toward valves (23) and (27) of the head assembly.

48. Install charge pump (2). Install bolts (1).
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    Illustration 58	g00581830

49. Use Tooling (C) and install retaining ring (51).
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    Illustration 59	g01002253

    Note: Lubricate the sealing lip with the lubricant that is being used.

50. Use Tooling (A) and Tooling (M) and install seal (50).
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    Illustration 60	g00581792

51. Use Tooling (C) in order to install retaining ring (49).

End By:

1. Install the hydraulic drive pump. Refer to Disassembly and Assembly, "Hydraulic Drive Pump - Install".