Removing and Installing Bushings and Pressure Plates in Hydraulic Gear Pumps {5073} Caterpillar

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Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

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Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Summary

This guideline explains how to remove and install bushings and pressure plates in hydraulic gear pumps and motors. This guideline gives the proper tooling for each group of gear pump.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for you and for other people to use. Ensure that the product will not be damaged. Ensure that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Using the correct tooling will ensure that the bushings are installed to the correct depth and the bushings are staked properly into the housing. Refer to Table 4 for the part numbers of the tooling that is required to service your pump.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Ensure that the tools, procedures, work methods, and operating techniques are safe. Ensure that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, ensure that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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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 attachments have been lowered, 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.

Reference Materials

Identification and Tooling

Using the correct tooling will ensure that the bushings are installed to the correct depth and the bushings are staked properly into the housing. Refer to Table 4 for the part numbers of the tooling that is required to service your pump.

Removing the Pressure Plates

The remover group allows easy removal of the pressure plates. Use the following procedure to remove the pressure plates.

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Illustration 3	g01521422
Pressure Plate Remover Group (1) Bolt (2) Large diameter (3) Draw collet

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Illustration 4	g01521426
Removing the pressure plate

1. Insert the large diameter (2) of the remover group into either bore of the pressure plate. Refer to Illustration 4.

2. Tighten bolt (1) of remover group. Tighten draw collet (3) into the remover group causing the large diameter (2) of the remover group to expand and grasp the pressure plate. Tighten bolt (1) until the pressure plate is firmly grasped. Do not overtighten bolt (1). Remove the pressure plate by oscillating and pulling upward on the remover group until the pressure plate is free from the pump housing.

Removing the Bushings

The bushings are pressed into the housing and staked into position. The bushings cannot simply be pulled out of the housing or damage to the housing may result. The bushing removal tool will split the wall of the bushing to allow easy removal of the bushing with pliers. Refer to the following procedure for removal of the bushings.

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Illustration 5	g03158286
Bushing Remover Tool

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Illustration 6	g01521438

1. Install bushing remover (4) into the bushing. Position the bushing installer so that hole (B) is located 180 degrees from the split in the wall of the bushing. Refer to Illustration 5.

   Installing a 5/16 - 18 bolt into the threaded hole (A) may be necessary. The bolt will lock the bushing to the bushing remover and prevent movement of the bushing. Refer to Illustration 6.

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   Illustration 7	g03158676

2. Drill through hole (B) and into bushing (5) by using a 9.5 mm (0.375 inch) drill. Use a suitable drill press that is operating at 1000 rpm or higher. Use a slow steady feed rate with lubricating oil. Refer to Illustration 7.

   Note: Do not drill past the bushing and into the housing. Periodically check the depth of the drill to make sure that you do not drill into the housing.

3. Once the bushing has been drilled through, remove the bushing remover tool. The bushing should now be split and the bushing can be easily removed with pliers.

Installing the Bushings

Aligning the Bushings

Illustration 8	g03158716

The bushings must be installed into the housing and staked into position. Install by using a suitable press that is able to attain 5 tons of force and the tooling that is listed in Table 4. Do not drive the bushings into the housings. The bushings must be installed so that the split in the bushings (D) and (E) is positioned toward the alignment dowels (C) and (F).The positioning of the bushings is shown in Illustration 8.

Illustration 9	g03158762

Illustration 10	g03160018

Some of the pumps use bushings that are equipped with lubrication grooves (H) and (J). These pumps need to have lubrication grooves (H) and (J) positioned toward the alignment dowels (G) and (K). The lubrication grooves will position the seam of the bushings approximately 30 degrees on either side of the alignment dowels (G) and (K). Refer to Illustrations 9 and 10. What side of the alignment dowels the seam of the bushing is located on does not matter.

Groups 1, 4, 5, and 6

Illustration 11	g03160085
Exploded View (6) Bolt (7) Washer (8) Cap (9) Sleeve (10) Shim (Group 4 only) (11) O-ring (12) Driver (13) Staking Leg (14) Guide

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Illustration 12	g01523695
Assembled View

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Illustration 13	g03160116

1. Assemble the guide (14), driver (12), staking legs (13), and shim (if required) (10) into the sleeve (9). The shim is only used for Group 4 pumps. The staking legs will need to be slightly tilted when the legs are installed into the sleeve, as shown in Illustration 12. Position the guide correctly depending on if you are pressing the bushings into aluminum housings or if you are pressing the bushings into iron housings.

   The end diameters of the guide are different in length. Diameter (L) should be extended out of the sleeve for pumps with iron housings. This will install the bushings flush with the housings. Diameter (M) should be extended out of the sleeve for pumps with aluminum housings. This will install the bushings extended out of the housings. Refer to Illustration 13.

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   Illustration 14	g03160198

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   Illustration 15	g01524004

2. The bushing bore of the pump housing has staking grooves machined into the housing. Locate the staking grooves and mark the location on the flat surface of the pump housing which will allow you to align the staking tool.

3. Install the cap (8), the washer (7), and the bolt (6) to hold the staking tool assembly together as a unit, as shown in Illustration 14. Install the bushing over the staking legs and the guide. The bushing should be seated against the shoulder of the guide.

4. Position the pump housing into a suitable press. Position the staking tool with the bushing into position. Align the bushing with the bushing bore of the housing. Make sure that the bushing is oriented correctly with the alignment dowels as determined at the beginning of this section. Make sure that the tips (N) of the staking tool are aligned with the marks for the staking grooves. Refer to Illustration 14. Remove the bolt and the washer from the top of the staking tool assembly. The cap should remain in position.

   Note: Make sure that the pump housing is installed level in the press. If the bushing bore of the housing and the bushing are not aligned properly, damage to the bushing and the pump housing can result.

5. Press the staking tool assembly and the bushing into the housing of the pump. Stop when the sleeve of the staking tool contacts the housing of the pump, as shown in Illustration 15.
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   Illustration 16	g03160377

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   Illustration 17	g01524045
   View of the bushing after the bushing is properly staked into position.

6. Retract the head of the press and remove the cap from the staking tool. The head of the press can now contact driver (12) of the staking tool. Press driver (12) down until the head of the press contacts sleeve (9). Do not use any more force than necessary. The bushing should now be staked into position.

7. Retract the press and replace the cap onto the staking tool assembly. Install the washer and the bolt into the staking tool assembly. Tighten the bolt until the driver releases the pressure on the staking legs. Carefully remove the staking tool assembly from the bushing. Some twisting motion may be required to remove the staking tool assembly. Refer to Illustrations 16 and 17.
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   Illustration 18	g01508987
   Plug Gauge. Dimensions shown are in inches.

8. Check the installation of the bushing. If the bushings are installed incorrectly, some of the bushing material will be expelled into the bore area for the gear shaft once the bushing is staked into position. Use the plug gauge to verify correct installation of the bushings in the housing. The plug gauge should slide through the bushing freely. If the plug gauge does not slide through the bushing freely, then there is an issue with the bushing. Remove the bushing and reinstall another bushing. Repeat the process until the plug gauge slides through the bushing freely.
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   Table 5

   Plug Gauge Dimensions
   Pump and Motor GP number	Dimension A
   1	44.63 mm (1.757 inch)
   4	44.63 mm (1.757 inch)
   5	47.70 mm (1.878 inch)
   6	47.70 mm (1.878 inch)

Groups 2, 3, 9, 10, and 11

Illustration 19	g03394247
(15) Sleeve (16) Guide (17) Staking leg (18) Setscrew (19) Cap

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Illustration 20	g03394250

1. The bushing bore of the pump housing has staking grooves machined into the housing. Locate the staking grooves and mark the location on the flat surface of the pump housing. The marking will allow you to align the staking tool.

2. Position the pump housing into a suitable press. Position the new bushing onto the pump housing and align the bushing with the bushing bore. Make sure that the bushing is oriented correctly with the alignment dowels as determined at the beginning of this section.

   Note: Make sure that the pump housing is installed level in the press. If the bushing bore of the housing and the bushing are not aligned properly, damage to the bushing and the pump housing can result.

3. Position sleeve (15) and cap (19) over the bushing. Press the bushing into the housing until sleeve (15) is against the pump housing, as shown in Illustration 20. Remove cap (19).
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   Illustration 21	g03394251

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   Illustration 22	g03394252

4. Position staking legs (17) into guide (16), as shown in Illustration 21. Then, install staking legs (17) and guide (16) into sleeve (15), as shown in Illustration 22.

5. Position staking tool assembly over the bushing in the pump housing. Make sure that the staking legs are aligned with the marks for the staking grooves that were made in the first step. Tighten setscrews (18) to hold staking legs (17) in position against guide (16).
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   Illustration 23	g03394264

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   Illustration 24	g01524455
   View of the bushing after the bushing is properly staked into position.

6. Press down on guide (16) until guide (16) is flush with staking legs (17). The bushing should now be staked into position. Refer to Illustrations 23 and 24.
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   Illustration 25	g01508987
   Plug Gauge. Dimensions shown are in inches.

7. Check the installation of the bushing. If the bushings are installed incorrectly, some of the bushing material will be expelled into the bore area for the gear shaft once the bushing is staked into position. Use the plug gauge to verify correct installation of the bushings in the housing. The plug gauge should slide through the bushing freely. If the plug gauge does not slide through the bushing freely, then there is an issue with the bushing. Remove the bushing and reinstall another bushing. Repeat the process until the plug gauge slides through the bushing freely.
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   Table 6

   Plug Gauge Dimensions
   Pump and Motor GP number	Dimension A
   2	31.81 mm (1.252 inch)
   3	39.70 mm (1.563 inch)
   9	31.81 mm (1.252 inch)
   10	39.70 mm (1.563 inch)
   11	31.81 mm (1.252 inch)