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Introduction
Revision | Summary of Changes in SEBF8161 |
24 | Updated Effectivity. |
24 | Updated Effectivity. |
23 | Updated Effectivity. |
22 | Updated Effectivity. |
© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealersonly. 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 guideline enables dealers and dealer customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current information known to Caterpillar Inc. Since the company makes ongoing product changes and product improvements, this guideline must be used with the latest technical information. Using the latest technical information available from Caterpillar ensures that such changes and improvements are incorporated where applicable.
For questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:
- Cat Dealer Technical Communicator
- Global Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
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 shows visual examples of worn hydraulic pump parts used on Caterpillar machines. Specifically, this guideline shows illustrations of gear pump parts, which can or cannot be used again with or without salvage (reconditioning) operations. This practical information is a list of items to remember any time you work with hydraulic gear pump parts. The list includes some basic reuse rules.
Parts that can be used again in the same application, according to this guideline, can be expected to give normal performance until the next overhaul.
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.
Improper operation, lubrication, maintenance, or repair of this product is dangerous. Improper methods could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand 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.
Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.
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. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for all personnel around the machine. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.
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
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. |
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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Never install a part again if this guideline shows that the part cannot be used again.
- Never use a part again if the part has wear or damage that is not shown in this guideline.
- As you look to see if a given part is reusable, be sure to remember the parts "cause and effect" in relation to other parts. Failure, wear, or damage to one part can affect the performance of connected parts.
- The following is an example of the source of a larger, future problem. There is light wear on the bearing diameter of the gear shaft. The wear is caused by contaminants (foreign material) that are embedded in the bearing bores. The condition of the bearing is not easily seen at this early stage. If a new bearing is not installed, the wear will gradually increase and cause a failure.
Illustration 3 | g01219580 |
Rear view of gear pump. |
The parts in hydraulic pumps work together to give flow or torque. The efficiency of a unit is variable according to the flow loss that any given group of parts permits.
References
References | |
Media Number | Title |
NENG2500 | "Dealer Service Tool Catalog" |
SEBF9236 | "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components" |
SEBF9238 | "Fundamentals of Arc Spray for Reconditioning Components" |
SEBF9240 | "Fundamentals of Flame Spray for Reconditioning Components" |
SEBF2129 | "Thermal Spray Procedures for Tyrone Drive Shaft (Pump Gear)" |
SEBF2144 | "Thermal Spray Procedures for Manifold - Oil Pump" |
Oerlikon Metco Inc. | www.oerlikon.com |
Tooling and Equipment
Optional Tools | |
Source | Description |
Lapmaster International (lapmaster.com)(lapmaster.com) | Lapping Machine |
Sunnen (sunnen.com) | Convex Barrel Lap Machine |
Cleaner (Hydrosolv 4110) |
Power Lapping Procedure
Power lapping can remove wear patterns and surface scratches. Power lapping will provide a "like new" surface flatness on parts. The power lapping machine can be used on a wide range of parts that require flat, smooth surfaces. Power lapping can produce flat surfaces within tolerances of one light band or
Lapping machines are easy to operate. However, some general guidelines must be followed. Check the lapping plates periodically, preferably every morning before starting production, to ensure lap plate flatness.
Fill the slurry tank with a lapping vehicle. The vehicle is purchased premixed and a lapping compound should be added to the vehicle at a rate of
Load the parts to be lapped inside the conditioning rings. The parts should be free to move about within the ring and not packed such that the parts remain stationary. Lapping times will vary according to the severity of the flaw that is to be removed. Minor scratches or warpage can usually be removed within 30 to 60 minutes. To inspect the flatness of the lapped part, remove the dull finish that is caused by the lapping compound. Wash the part thoroughly. Polish the lapped surface, using 600 grit emery paper on a 4/0 polishing stand, until the part will reflect light.
Testing For Flatness
Illustration 4 | g03431728 |
Optical flat. |
A monochromatic light source and an optical flat are required to determine flatness. Refer to Illustration 4.
Illustration 5 | g03431756 |
Light band pattern. |
Test for flatness by observing the light, emitted from the monochromatic light head, reflecting from the surface being checked, up through the optical flat. A series of dark bands and light spaces will be projected. Refer to Illustration 5. The dark bands are not light rays, but show where interference is produced by reflections from the test piece in the optical flat. Inspect the light bands for straightness. If the bands are straight and parallel, the surface is flat. If the bands are curved, the surface is not flat but may be flat enough for your particular needs.
Flange, Plate, and Body Assemblies
Nomenclature
Illustration 6 | g01224155 |
(1) Seal
(2) Manifold As. (3) Bearing (4) Gear (5) Body As. (6) Bearing (7) Manifold As. (8) Washer (9) O-ring Sea (10) Bolt (11) Plug (12) Bolt (13) Bolt (14) Plug (15) O-ring Sea (16) O-ring Sea (17) Dowel (18) Gear As. |
Cleaning Procedure
Before a part is inspected, wash the part in a clean solvent that is made from petroleum. Wash each part separately. If several parts are washed together, there is a possibility that a machined surface can be damaged. Use compressed air to dry the part. Put hydraulic oil on the part to prevent rust or corrosion. Put the part in a clean container. Use a lint-free towel to clean the part before assembly. Put oil on all of the parts during assembly.
Note: When you handle or put pump parts in storage, care must be taken to prevent damage to the machined surfaces.
Mounting Face
Illustration 7 | g03430493 |
Use again
Use again if the mounting face is free of scratches and nicks. Be sure that the damage does not extend to O-ring grooves and can be removed by hand lapping.
Gear Track
Illustration 8 | g03430450 |
Light wear-in of gear track and no raised burr along edge of track. |
Use again
Use again if the damage caused by foreign material in the low-pressure side of the gear track will not have a negative effect on performance.
Illustration 9 | g03430490 |
Raised burr on side of gear track. |
Do not use again
Do not use again if there is a raised burr of
Illustration 10 | g03430511 |
Wear-in of gear track with raised burr along edge of track. |
Do not use again
Do not use again if there is a raised burr of greater than
Cavitation
Illustration 11 | g03317226 |
Cavitation erosion on face of manifold surface. (19) Root of Gear Tooth (20) Edge of Outlet (Two Places) (21) Cavitation Erosion Permitted in Cross Hatched Area |
Use again
Use again if the cavitation erosion in one location has a depth less than
Cracking
Illustration 12 | g03430517 |
Crack through bolt hole in body assembly. |
Manifold Surface
Illustration 13 | g03430524 |
Scratches on face of manifold assembly. |
Use again
Use again if scratches can be removed by power lapping or surface grinding.
Illustration 14 | g01221206 |
Gear has moved into face of cover. Blackened area may have a harder surface than the surrounding area. |
Use Again
Use after damage has been removed by power lapping or grinding according to specification listed in Section “Salvage Specifications” in this guideline.
Refer to “Power Lapping Procedure” section in this guideline.
Cover Surface
Illustration 15 | g01221208 |
Gear has moved into the face of the cover. |
Use again
Use again after damage has been removed by power lapping or grinding according to specification listed in Section “Salvage Specifications” in this guideline.
Illustration 16 | g01221214 |
Cover after grinding according to specifications listed in the Section“Salvage Specifications”. |
Nomenclature
Illustration 17 | g01221218 |
Gear Shaft nomenclature (A) Tooth Profile (B) Tooth Face (C) Spline (D) Seal Area (E) Bearing Area |
Cleaning Procedure
Wash gears with a clean solvent made from petroleum. Clean carefully so as not to damage bearing areas. Removing discoloration (change of color) from the gears is not necessary. Discoloration is caused by oil and is acceptable.
Bearing Area
Illustration 18 | g01221220 |
Bearing area shows light scratches that can be felt with a fingernail or pencil lead. |
Use again
Use again after scratches are removed with 400 grit crocus cloth and motor oil. Install in a lathe and use a flat file behind the crocus cloth to polish bearing and tooth face areas.
Illustration 19 | g01221232 |
Grooves in the bearing area can be felt with a fingernail or pencil lead. |
Use again
Use again after the bearing area is salvaged by using metal spray procedures.
Note: Worn or damaged surfaces which can be salvaged by chrome plating can also be salvaged by a metal spray process. See Reuse and Salvage Guideline, SEBF9236, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components", Reuse and Salvage Guideline, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components" and Reuse and Salvage Guideline, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components" for information about metal spray repair processes. You can also consult the metal spray equipment manufacturer for powder, machine settings, and machining information. Oerlikon Metco Inc. is one manufacturer of metal spray equipment. Check with the manufacturer of the metal spraying equipment for exact surface preparation and spraying recommendations.
Gear Face
Illustration 20 | g03431167 |
Gear face has experienced excessive heat and metal transfer. |
Do not use again
Illustration 21 | g03431747 |
Gear is damaged due to contamination. |
Tooth Face
Illustration 22 | g03431187 |
Gear has been overheated. Gear teeth are scratched and tooth profile shows wear damage. |
Shaft Area
Illustration 23 | g01222103 |
Damage to end of second section drive gear. |
Seal Area
Illustration 24 | g01222105 |
Grooves in the seal area can be felt with a fingernail or pencil lead. |
Use again
Use again after the seal area is salvaged by Metal Spray procedures.
Salvage Specifications
The following information can be used to make repairs to the drive or idler gears. Use Metal Spray procedures to restore the diameter and surface finish to salvaged parts.
Table B - Salvage Specifications | ||
---|---|---|
Item | Gear Shaft Diameter | Surface Finish RA |
A | |
|
B | |
|
C | |
|
D | |
|
E | |
|
F | |
|
G | |
|
H | |
|
J | |
|
Part No. | Name | Item |
---|---|---|
Gear | F | |
Gear | F | |
Gear | F | |
Gear | F | |
Gear | C | |
Gear | C | |
Gear | E | |
Gear | E | |
Gear | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear | G | |
Gear | G | |
Gear As. | E | |
Gear As. | F | |
Gear | G | |
Gear | G | |
Gear | G | |
Gear | G | |
Gear As. | E | |
Gear | G | |
Gear | G | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear | A | |
Gear | D | |
Gear | D | |
Gear | D | |
Gear As. | F | |
Gear As. | F | |
Gear | F | |
Gear As | F | |
Gear As. | F | |
Gear | F | |
Gear | F | |
Gear | F | |
Gear | F | |
Gear | F | |
Gear | G | |
Gear | G | |
Gear | G | |
Gear | G | |
Gear | H | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear | B | |
Gear | B | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | G | |
Gear As. | G | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | B | |
Gear As. | B | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear | G | |
Gear | G | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear | A | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | A | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | A | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | E | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | G | |
Gear As. | G | |
Gear | F | |
Gear | F | |
Gear As. | F | |
Gear | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | G | |
Gear As. | G | |
Gear | F | |
Gear As. | E | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | G | |
Gear As. | G | |
Gear | G | |
Gear As. | F | |
Gear As. | F | |
Gear As. | J | |
Gear As. | J | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear As. | F | |
Gear | F | |
Gear | F |
Before installing the bearing, ream the bore to the correct size.
Table D - Reamer Size Dimension | |
---|---|
Bearing Size | Reamer Size |
|
|
|
|
|
|
When reaming through a hole, always enter the hole from the backside. When reaming a blind hole, use a small grinder to remove the burr at the top of the bore. If this procedure is not followed, the reamer will possibly catch on the burr and not follow the bearing bore diameter. A hole not reamed correctly will result in the part being scrapped.
The bearing must be installed with a bearing driver and arbor press.
Illustration 25 | g03357818 |
The bearing joint (V) must be 30 ± 15° from a center line, which passes through the bearing, bore mounting holes. Refer to Illustration 25.
The bearing must be recessed to dimension (Z), 1.57 mm (0.062 inch) below the surface. Refer to Illustration 25.
The surface texture (W) of the manifold or cover must be
The depth of stock removal is limited to the bearing bore depth (X) minus the total length of the bearing (Y) plus
EXAMPLE:
X - Y + Z = Minimum Stock Removal
This step will normally allow
Table E - O-ring Groove Dimensions | |
---|---|
Item | Dimensions |
S | |
T | |
U | |
The O-ring groove depth (U) must be