Operation and Maintenance of 9U-6600 And 4C-4865 Pump Groups{615} Caterpillar

Operation and Maintenance of 9U-6600 And 4C-4865 Pump Groups{615}

Usage:

Caterpillar Service Tool

Introduction

This publication contains operation, maintenance, and parts information for the 9U-6600 and 4C-4865 Pump Groups. These manually operated hand pumps can be used for hydraulically actuated tool attachments. This publication also includes parts information for the former 6V-9061 Pump Group. The 6V-9061 Pump Group was canceled and replaced by the 4C-4865 Pump Group.

For information about parts listed without Caterpillar part numbers, call Caterpillar Service Technology Group at the telephone numbers listed below. Regular business hours are from 8:00 AM to 4:30 PM Central Standard Time.

Within the state of Illinois:

1-800-541-8665

Outside the state of Illinois:

1-800-542-8665

Canada:

1-800-523-8665

Customers may also contact the Caterpillar Service Technology Group through the TELEX. Our number is 404435.

Specifications

9U-6600 Pump Group

Capacity

The reservoir (tank) capacity is 7.9 liters (2.05 U.S. Gallons).

Usable capacity is 7.6 liters (1.98 U.S. Gallons).

Oil

Use SAE10 non-detergent petroleum oil.

Weight

26.7 kg (58.74 lb).

Size

308 × 321 × 735 mm (12.1 × 12.6 × 28.9 in)

Valve Port Size

3/8 inch NPT

Pump Pressure and Volume

Hydraulic Schematic

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

(1) High pressure seal. (2) High flow inlet cone. (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.

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

(1) High Pressure Seal. (2) High Flow Inlet Cone. (3) Dump Valve Piston Seal. (4) Low Flow Inlet Ball. (5) Low Flow Outlet Ball. (6) High Flow Outlet Ball. (9) Dump Valve Piston Area.

During the exhaust stroke, low flow inlet ball (4) and high flow inlet cone (2) close and prevent the flow of oil back to the tank. Low flow outlet ball (5) and high flow outlet ball (6) opens and allows oil flow to the valve. With low pressure in dump valve piston area (9), dump valve piston seal (3) does not move high flow inlet cone (2) from the closed position.

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

(1) High pressure seal. (2) High flow inlet cone. (3) Dump valve piston seal. (4) Low flow inlet ball. (5) Low flow outlet ball. (6) High flow outlet ball. (9) Dump valve piston area.

During the inlet stroke, high flow inlet cone (2) opens and the "high flow" piston area (7) fills with oil, and low flow inlet ball (4) opens to let "low flow" piston area (8) fill. Low flow outlet ball (5) and High flow outlet ball (6) are closed. Because of the higher system pressure in dump valve piston area (9), dump valve piston seal (3) moves and holds high flow inlet cone (2) open.

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

(1) High pressure seal. (2) High flow inlet cone. (3) Dump valve piston seal. (4) Low flow inlet ball. (5) Low flow outlet ball. (6) High flow outlet ball. (9) Dump valve piston area.

During the exhaust stroke with high system pressure, low flow inlet ball (4) and high flow outlet ball (6) close and prevent the flow of high pressure oil back to the tank. Because of the high pressure in dump valve piston area (9), dump valve piston seal (3) holds high flow inlet cone (2) open allowing "high flow" return oil to go back to the tank. Any oil leakage from high pressure seal (1) and dump valve piston seal (3) returns to the tank.

Shear Seal Valve Schematic

Handle Position (A)

With the 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.

Handle Position (B)

With the handle at position (B), all ports, C1, C2, pressure and tank are closed.

Handle Position (C)

With the handle 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

Show/hide table

Oil under high pressure can cause personal injury. DO NOT allow high pressure oil to contact skin. Wear appropriate protective equipment while working with high pressure oil systems.

1. Check the reservoir (tank). If the tank level is low, fill the tank with SAE 10W non-detergent oil.

2. Install hoses (1) and (2), and handle (3).

3. Open vent plug (5) on the filler cap. The vent valve is opened to prevent cavitation (production of air bubbles) in the system.

4. Connect hoses (1) and (2) to a cylinder or hydraulically actuated tool.

5. Select the direction of oil flow with valve handle (4).

When valve handle (4) is at position (A), oil flows out of hose (1) and returns through hose (2).

When valve handle (4) is at position (B), both hoses (1) and (2) are closed.

When valve handle (4) is in position (C), oil flows out of hose (2) and returns through hose (1).

6. Move handle (3) up and down to activate pump.

NOTE: The pump has two travel speeds (flows). At pressures up to 1380 kPa (200 psi), the "high flow" and "low flow" piston areas both supply oil to the directional valve. At approximately 1380 kPa (200 psi), the dump valve piston shifts. This allows the "high flow" piston area oil to return to the tank and the "low flow" piston area supplies oil to the directional valve. This shift occurs automatically, but may require a momentary relaxing of downward pressure on the pump handle during the pumping stroke at time of shift.

Adjusting Pressure Relief Valves

Maximum pump pressure is controlled by one of two relief valves. The safety relief valve (2) is preset at the factory at 69,000 kPa (10,000 psi). Do Not adjust this relief valve.

The secondary relief valve (1) is preset at approximately 3445 kPa (500 psi) above the primary relief valve (2). This relief valve prevents sudden pressure spikes caused by load from returning to the pump. The secondary relief valve (1) may be adjusted to lower maximum pressure to below 69 000 kPa (10,000 psi). In order to adjust this valve, the top of the pump group has to be removed from the reservoir to access the valve (1). Turn the screw counterclockwise (CCW) to lower relief valve pressure or clockwise (CW) to increase the relief valve pressure.

9U-6600 Basic Pump Group And Torque Specifications

Illustration 1.

Illustration 2.

9U-6600 Hand Pump Group Parts List And Torque Specifications

Illustration 3.

9U-6600 Pump Group Assembly (under top) Parts List And Torque Specifications

Illustration 4.

4C-4367 Shear Valve Parts List

Illustration 5.

Troubleshooting The 9U-6600 Pump

The following, lists possible problems, cause and corrections. Before making any repairs or adjustments, refer to the notes that follow the troubleshooting guide and diagram.

Troubleshooting Index

* Pump does not operate

* Gauge does not operate

* Loss of output pressure and flow

* Outside leakage

* Notes

Pump Does Not Operate

Cause: No oil in pump.

Correction: Fill with SAE 10 non-detergent oil.

Cause: Closed air vent in filler plug [(3) Illustration 1].

Correction: Open vent plug.

Cause: Dirty inlet screens [(20) Illustration 1, or (12) Illustration 3].

Correction: Clean or install new screens.

Cause: Dirty oil.

Correction: Flush and refill reservoir (tank) with clean oil.

Cause: Damaged shear seal valve (Illustration 5).

Correction: Make repairs or install new valve (refer to notes).

Cause: Broken tube or gauge [(6, 7, 8) Illustration 4].

Correction: Install new gauge.

Cause: Leakage through U-cup packing [(33) Illustration 2].

Correction: Install new U-cup packing.

Cause: Dirt in outlet ball [(19) Illustration 2] for large pump area.

Correction: Flush, clean and fill pump with clean oil (refer to Note 2).

Cause: Dirt in inlet ball [(22) Illustration 2, and cone (10) Illustration 3].

Correction: Flush, clean and fill pump with clean oil.

Cause: Fittings on tubes loose or disconnected [(15) Illustration 2].

Correction: Tighten fittings or install new tubing.

Gauge Does Not Operate

Cause: Gauge linkage not moving.

Correction: Install new gauge.

Cause: Broken tube in gauge.

Correction: Install new gauge.

Cause: Loose fittings on tube [(7 or 8) Illustration 4].

Correction: Tighten fittings.

Loss Of Output Pressure And Flow

Cause: Damaged shear seal valve (Illustration 5).

Correction: Make repairs or install new shear seal valve (refer to notes).

Cause: Dirty high/low flow inlet and/or outlet balls.

Correction: Clean, flush and fill shear seal valve with clean oil.

Cause: Failure of relief valve [(4) Illustration 4].

Correction: Install new relief valve.

Cause: Adjustable relief valve [(8) Illustration 2] set too low.

Correction: Adjust screw (A).

Cause: Failure of gauge [(6) Illustration 4].

Correction: Install new gauge.

Cause: Loose fittings on tube [(15) Illustration 2].

Correction: Tighten fittings.

Outside Leakage

Cause: Damaged shear seal valve (Illustration 5).

Correction: Make repairs or install new valve (refer to notes).

Cause: Defective cover gasket [(34) Illustration 2].

Correction: Install new gasket.

Cause: Defective wiper [(1) Illustration 2] on plunger.

Correction: Install new wiper.

Cause: Defective O-ring [(4) Illustration 2].

Correction: Install new gasket.

Cause: Defective top cap gasket [(2) illustration 2].

Correction: Install new gasket.

Cause: Defective outlet port threads.

Correction: Make repairs.

Cause: Damaged reservoir (tank) assembly [(25) Illustration 2].

Correction: Make repairs.

Notes:

1. Before disassembling shear seal valve (Illustration 5), first check to see if the pump sends oil to the valve. To do this, disconnect tube [(15) Illustration 2] from the Hex Adapter [(9) Illustration 2], and operate the pump. Pump flow should be approximately as follows:

119 mL (7.3 cu in) per stroke at 1720 kPa (250 psi) maximum, or;

4.8 mL (0.29 cu in) per stroke at pressure greater than 1720 kPa (250 psi).

2. Check operation of outlet check balls [(19) Illustration 2] 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. (Refer to the shear valve diagram and parts list, Illustration 5).

4. Relief valve [(4) Illustration 4] is preset at the factory to 69 000 to 72 345 kPa (10,000 to 10,500 psi). Do Not adjust this factory set safety valve.

5. Relief valve [(8) Illustration 2] is set at approximately 74 412 to 77 168 kPa (10,800 to 11,200 psi) at the factory. Maximum pump output pressure can be lowered by turning the valve counterclockwise.

Troubleshooting The 4C-4865 Pump

The following, lists possible problems, cause and corrections. Before making any repairs or adjustments, refer to the notes that follow the troubleshooting guide and diagram.

Troubleshooting Diagram

Illustration 6.

Troubleshooting Index

* Pump does not operate

* Gauge does not operate

* Loss of output pressure and flow

* Outside leakage

* Notes

Pump Does Not Operate

Cause: No oil in pump.

Correction: Fill with SAE10 non-detergent oil.

Cause: Closed air vent in filler plug (50).

Correction: Open vent plug.

Cause: Dirty inlet screens (34 and/or 37).

Correction: Clean or install new screens.

Cause: Dirty oil.

Correction: Flush and refill reservoir (tank) with clean oil.

Cause: Defect in shear seal valve (62).

Correction: Make repairs or install new valve (refer to notes).

Cause: Broken tube in gauge (79).

Correction: Install new gauge.

Cause: Leakage through U-cup packing (18).

Correction: Install new U-cup packing.

Cause: Dirt in outlet ball (35) for large pump area.

Correction: Flush, clean and fill pump with clean oil (refer to note 2).

Cause: Dirt in inlet ball (36) and cone (45).

Correction: Flush, clean and fill pump with clean oil.

Cause: Fittings on tubes (30) and (85) loose or disconnected.

Correction: Tighten fittings or install new tubing.

Gauge Does Not Operate

Cause: Gauge linkage not moving.

Correction: Install new gauge.

Cause: Broken tube in gauge.

Correction: Install new gauge.

Cause: Loose fittings on tube (85).

Correction: Tighten fittings.

Loss Of Output Pressure And Flow

Cause: Defect in shear seal valve (62).

Correction: Make repairs or install new shear seal valve (refer to notes).

Cause: Dirty high/low flow inlet and/or outlet balls.

Correction: Clean, flush and fill shear seal valve with clean oil.

Cause: Failure of relief valve (19).

Correction: Install new relief valve.

Cause: Adjustable relief valve (32) set too low.

Correction: Adjust screw (A).

Cause: Failure of gauge (79).

Correction: Install new gauge.

Cause: Loose fittings on tube (30).

Correction: Tighten fittings.

Outside Leakage

Cause: Defect in shear seal valve (62).

Correction: Make repairs or install new valve (refer to notes).

Cause: Defective cover gasket (59).

Correction: Install new gasket.

Cause: Defective wiper (11) on plunger.

Correction: Install new wiper.

Cause: Defective gasket (67).

Correction: Install new gasket.

Cause: Defective top cap gasket (6).

Correction: Install new gasket.

Cause: Defective gauge gasket (80).

Correction: Install new gasket.

Cause: Defective outlet port threads.

Correction: Make repairs.

Cause: Damaged reservoir (tank) assembly (60).

Correction: Make repairs.

Notes:

1. Before disassembling shear seal valve (62), check to see if the pump sends oil to the valve. To do this, disconnect tube (30) from the shear seal valve and operate the pump. Pump flow should be approximately as follows:

119 mL (7.3 cu in) per stroke at 1720 kPa (250 psi) maximum, or;

4.8 mL (0.29 cu in) per stroke at pressure greater than 1720 kPa (250 psi).

2. Check operation of outlet check balls (35) 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. (Refer to the shear valve diagram and parts list).

4. Relief valve (19) is preset at factory to 69,000 to 72,345 kPa (10,000 to 10,500 psi). Do Not adjust this factory set safety valve.

5. Relief valve (32) is set at approximately 74,412 to 77,168 kPa (10,800 to 11,200 psi) at the factory. Maximum pump output pressure can be lowered by turning adjusting screw (A) counterclockwise. Adjusting screw (A) is located under fill plug (48). (Customer adjustable relief valve).

4C-4864 Basic Pump Group Parts

Illustration 7.

Pump Unit Disassembly

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

2. Remove lockwasher (15), screen (14), and screen (16).

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

4. Remove plug (27), gasket (26), O-ring (21), and back-up ring (20).

5. On the opposite side, remove plug (1), gasket (2), spring (3), cone (4), and spring (17). Push out plunger (19) and spring (18).

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

Pump Unit Assembly

1. Clean all parts thoroughly.

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

3. Install screen (14) and lockwasher (15). Install screen (16).

4. Install gasket (11) and safety valve (12).

5. Install balls (22) and (25), spring (23) and connector (24).

6. Install cone (4), spring (3), gasket (2) and plug (1).

7. Insert plunger (19), with springs (17) and (18). Install back-up (20), O-ring (21), gasket (26) and plug (27).

8. Install U-cup (6), in pump body (13), with the open end of the cup down.

9. Install retaining nut (5), in the pump body. Tighten nut (5), to a torque of 1.4 to 2.1 N·m (12.46 to 18.69 lb in) and stake (centerpunch).

Parts Information

4C-4865 Pump Group ... 18

4C-4867 Shear Valve ... 20

4C-4860 Pump Service Kit ... 21

4C-4866 Shear Valve Kit ... 22

4C-4864 Pump Group Basic ... 16

4C-4867 Shear Valve Basic ... 23

4C-4861 Hook Assembly Kit ... 23

4C-4862 Beam/Plunger Pin Kit ... 24

4C-4863 Fill Plug Kit ... 24

4C-4865 Pump Group

Illustration 8.

4C-4865 Pump Group Parts

4C-4867 Shear Valve

Illustration 9.

4C-4867 Shear Valve Parts

4C-4860 Pump Service Kit

Illustration 10.

4C-4866 Shear Valve Kit

Illustration 11.

4C-4867 Shear Valve Basic

Illustration 12.

4C-4861 Hook Assembly Kit

Illustration 13.

4C-4862 Beam/Plunger Pin Kit

Illustration 14.

4C-4863 Fill Plug Kit

Illustration 15.

6V-9061 Pump Group

The 6V-9061 Pump Group has been canceled and replaced by the 4C-4865 Pump Group. The following illustration and charts identify the serviced components of the 6V-9061 Pump Group.

Illustration 16.