Operation And Maintenance Of 6V9061 Pump Group{0623} Caterpillar

Operation And Maintenance Of 6V9061 Pump Group{0623}

Usage:

Hydraulic Schematic

1 High Pressure Seal

2 High Flow Inlet Ball

3 Dump Valve Piston Seal

4 Low Flow Inlet Ball

5 Low Flow Outlet Ball

6 High Flow Outlet Ball

7 High Flow Piston Area

8 Low Flow Piston Area

9 Dump Valve Piston Area

Inlet Stroke With Less Than 1380 To 1720 kPa (200 To 250 psi) System Pressure

(A) On the inlet stroke, inlet ball (2) opens and the "high flow" piston area (7) fills with oil; inlet ball (4) opens to let "low flow" piston area (8) fill. Outlet balls (5) and (6) are closed.

Exhaust Stroke With Less Than 1380 To 1720 kPa (200 To 250 psi) System Pressure

(B) On the exhaust stroke, inlet balls (2) and (4) close and prevent the flow of oil back to the tank. Outlet balls (5) and (6) open and let oil flow to the valve. With low pressure in area (9), dump valve (3) does not move inlet ball (2) from the closed position.

Inlet Stroke With More Than 1380 To 1720 kPa (200 To 250 psi) System Pressure

(C) Same as procedure (A), except that with the increased pressure in dump valve area (9), dump valve piston (3) moves and holds inlet ball (2) open.

Exhaust Stroke With More Than 1380 To 1720 kPa (200 To 250 psi) System Pressure

(D) Same as procedure (B), except that with the increased pressure in area (9), dump valve (3) holds inlet ball (2) open and "high flow" return oil goes back to the tank. Inlet ball (4) and outlet ball (6) also close and prevent high pressure oil from going to the tank. Any oil leakage through seals (1) and (3) moves back to the tank.

Shear Seal Valve Schematic

(1) With the valve handle at position (A), oil flows from the pump through C1 port to move an outside cylinder forward; return oil moves through C2 port to the tank. At position (B), all ports, C1, C2, pressure and tank are closed. At position (C), oil flows from the pump through C2 port and the cylinder is retracted; return oil flows through C1 port to the tank.

Operation

(1) Fill the reservoir (tank) with approximately 7.6 liters (2 gallon) of SAE 10 non-detergent oil. Install hoses (1) and (2), and handle (3). Tighten the threaded screw to hold the handle in place.

(2) Valve handle (4) controls the direction of oil flow as shown through hoses (1) and (2). When handle (4) is at location (B), both hoses (1) and (2) are closed.

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NOTICE

Before operating the pump, open vent plug (5) on the filler cap to prevent cavitation (vacuum bubbles) in the system.

Maintenance

(1) The pump has two travel speeds. At oil pressure up to 1380 kPa, -0, +345 (200 psi, -0 +50), the cylinder piston moves rapidly; at 1380 kPa, -0, +345 (200 psi, -0, +50), low speed piston movement engages automatically, up to the relief valve setting of 69 000 kPa, -0, + 2050 (10,000 psi, - 0, +300). To check the high speed setting (with a low pressure gauge similar to an 8M2886 Gauge) connect the gauge to the end of one hose. Operate the handle slowly until the sequence valve operates. The gauge should read 1380 kPa, -0, +345 (200 psi, -0, +50). Add shims (1) to the valve to increase the setting, or remove shims (1) to decrease the setting. Each shim changes the setting 170 kPa (25 psi). Remove the gauge.

(2) The maximum pressure setting can be checked by operating the pump until relief valve operation is felt; the needle should be directly at 69 000 kPa (10,000 psi) on gauge (2). To make the setting of the relief valve higher, turn setscrew (3) clockwise; to make the setting lower, turn setscrew (3) counterclockwise.

Specifications

Reservoir (tank) Capacity: ... 7.9 liters (2.1 gallons)

Usable Capacity: ... 7.6 liters (2.0 gallons)

Fluid: ... SAE 10 non-detergent petroleum oil

Weight (including oil): ... 26.3 kg (58 lbs.)

Valve Port Size: ... 1/4"-18 pipe thread

Approximate Size: ... 940 x 280 x 280 mm (37" x 11" x 11")

Disassembly Of 6V9061 Pump

(1) Remove pin (1), handle (2) and grip (3).

(2) Remove two hoses (4). Remove four bolts (5) and lift the complete shear seal valve assembly (6) from manifold plate (7). (See shear seal valve disassembly and assembly, pages 10 and 11.)

(3) Remove eight bolts (8) and lockwashers (9). Remove cover assembly (10) and all connected parts from reservoir (tank) assembly (11). Remove gasket (12), filler plug (13) and O-ring (14).

(4) Remove retainer rings (15), beam pin (16) and beam (17). Push out pin (18). Remove bolt (19), two washers (20), hook (21) and wave washer (22).

(5) Remove three screws (23) and locknuts (24). Disconnect tube (25) from gauge (26) and tee (27). Remove connector (28). Do not remove screen (29) from the connector. Lift off gauge assembly (26) and gasket (30).

(6) Disconnect tube (31) from tee (27) and pump assembly (32). Remove three bolts (33), manifold plate (7), gasket (34), tee (27) and connector (43).

(7) Remove four bolts (35), five copper gaskets (36), bracket (37) and top cap (38). Remove wiper (39), if a new one is to be installed. Remove gasket (40), plunger (41), cylinder (42), and pump assembly (32).

Assembly Of 6V9061 Pump

(1) Clean all parts thoroughly.

(2) Install connector (43) to manifold plate (7) with pipe sealant. Install manifold plate (7) to cover (10) using gasket (34) and three bolts (33).

(3) Install tee (27) to connector (43); do not tighten.

(4) Install connector (28) to gauge assembly (26) with pipe sealant. Install gauge (26) to cover (10) using gasket (30), three bolts (23) and locknuts (24).

(5) Assemble plunger assembly (41) and cylinder (42) [with hole (A) at the top] to pump assembly (32). Hold this assembly in place on the bottom side of cover (10). Install wiper (39) in top cap (38). Install gasket (40), top cap (38), five copper gaskets (36), bracket (37) and four bolts (35). Use two copper gaskets (36) with brackets (37) as shown and install one gasket each with the other three bolts (35).

(6) Connect tube (31) to pump assembly (32) and tee (27); do not tighten.

(7) Connect tube (25) to gauge connector (28) and tee (27).

(8) TIGHTEN ALL FITTINGS AND TUBES.

(9) Install the complete cover assembly (10) on reservoir (tank) assembly (11), using gasket (12), eight lockwashers (9) and bolts (8). Tighten bolts (8) to a torque of 1.11 to 1.24 N·m (8 to 9 lb.ft.).

(10) Install shear seal valve assembly (6) using four bolts (5). Tighten bolts (5) to a torque of 7.6 N·m (55 lb.ft.).

(11) Install pin (18), with the flat section down, into beam (17). Install beam (17) over plunger assembly (41) and engage pin (18) with the slot in plunger (41). Move beam (17) so the holes in the beam are in alignment with the holes in top cap (38). Install pin (16) and snap rings (15). Install wave washer (22), one washer (20), hook (21), the other washer (20) and bolt (19).

(12) Slide handle (2) into beam (17) and install threaded pin (1). Install grip (3).

(13) Connect two hoses (4) and couplers (47).

(14) Fill the reservoir (tank) with clean oil and install O-ring (14) and filler plug (13).

Trouble Shooting Procedure

NOTE:

1. Before disassembling shear seal valve (6), first check to see if the pump sends oil to the valve. To do this, disconnect tube (31) from the shear seal valve and operate the pump. Pump flow should be approximately as follows:

117 mL (7.14 cu.in.) per stroke at 1720 kPa (250 psi) maximum

4.2 mL (.257 cu.in.) per stroke at pressure more than 1720 kPa (250 psi)

2. Check operation of outlet check balls (50) and (53) by application of pressure to the outlet port with a different pump.

3. If the pump is operating correctly and the shear seal valve is not, disassemble the valve. (See topic, DISASSEMBLY OF SHEAR SEAL VALVE ASSEMBLY, pages 10 and 11.)

Disassembly Of Shear Seal Valve

(1) Remove screw (1), washer (2) and handle (3).

(2) Remove detent plate (4), detent ball (5), and detent spring (6).

(3) Remove four O-rings (8) and two bolts (9).

(4) Remove valve body assembly (10) and spacer shim (24).

(A) Remove three shear seals (11); two backup rings (12) and one O-ring are on each shear seal.

(B) Remove three wave washers (14) from below the shear seals.

(5) Remove O-ring (15) from cap (16). Remove roll pin (7) only if necessary.

(6) Remove shaft (17), disc (18), bearing (19) and bearing plate (20).

(7) Remove back-up ring (21) and O-ring (22) from shaft (17).

(8) Remove roll pin (23). Remove shaft (17) from disc (18).

Assembly Of Shear Seal Valve

(1) Clean all parts thoroughly.

(2) Assemble one O-ring (13) and two back-up rings (12) to each of the three shear seals (11).

NOTE: Install back-up rings with the openings opposite each other.

(3) Install three wave washers (14) into valve body (10).

(A) Do not install a shear seal (11) in the "tank" port.

(B) Put lubricant on O-ring (13) and back-up rings (12) and install the shear seals in valve body (10).

(4) Assemble disc (18) to shaft (17) using roll pin (23).

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NOTICE

When installing disc (18) on shaft (17), make sure the holes in the face of the disc are toward valve body (10).

(5) Install O-ring (22) and back-up ring (21) in the groove on shaft (17).

(6) Install bearing plate (20) and bearing (19) in the counterbore of cap (16).

(7) Put lubricant on O-ring (22) and back-up ring (21). Install the shaft and disc assembly in cap (16).

(8) Install spacer shim (24).

(9) Install body (10) and shear seal assembly to cap (16) using O-ring (15) and two bolts (9).

(10) Install detent spring (6), detent ball (5) and detent disc (4).

(11) Install handle (3), washer (2) and machine screw (1).

(12) Put lubricant on four O-rings (8) and install the O-rings in the bottom side of valve body (10).

(13) The shear seal valve is now completely assembled and can be installed on the manifold plate of the pump cover assembly.

Disassembly Of Pump Unit

(1) Remove relief valve (12) and gasket (11).

(2) Remove retaining nut (5) and U-cup (6).

(3) Remove lockwasher (15) and screens (14) and (16).

(4) Remove connector (24), spring (23) and balls (25) and (22).

(5) Remove plug (27), gasket (26), piston (19), spring (18), shim washers (17) (quantity may change, see Maintenance, page 4). If replacement parts are not needed, it is not necessary to remove O-ring (21) and back-up (20) from piston (19).

(6) On the opposite side, remove plug (1), gasket (2), spring (3) and ball (4).

(7) Remove plug (7), gasket (8), ball (9) and spring (10).