Repair Process for Hydraulic Gear Pumps {5073} Caterpillar


Repair Process for Hydraulic Gear Pumps {5073}

Usage:

MT700 018
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Material Handler
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Pipelayer
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Telehandler
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Track Feller Buncher
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Introduction

Table 1
Revision  Summary of Changes to SEBF9091 
22  Added new serial number prefixes. 
21  Added new serial number prefixes. 
20  Added new serial number prefixes. 
19  Added new serial number prefixes. 

© 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

  • Dealer Solution Network

  • Caterpillar 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

The purpose of this document is to show the workflow through a Hydraulic Rebuild Shop.

When used in the same application, parts that can be used again can be expected to give normal performance until the next overhaul.

During reconditioning, correct any conditions that might have caused the original failure.

Important Safety Information



Illustration 1g02139237

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.

------ WARNING! ------

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 2g00008666

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

------ WARNING! ------

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.


------ WARNING! ------

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.


Reference Information

Table 2
References 
SERF8918  "Service Operation Development and Assessment (SODA)" 
SEBF8161  "Hydraulic Gear Pumps Used in Transmissions" 
SEBF8073  "Specifications and Reusability for Hydraulic Gear Pumps and Motors" 
SEBF8355  "Cleaning Guide Equipment and Chemical Recommendations Contents" 
NENG2500  "Dealer Service Tool Catalog" 
REHS1832  "Bench Test Procedure for Gear Pumps" 
PECJ0003  "Cat Hand Tools and Shop Supplies" 
SIS Web  Disassembly and Assembly manuals for applicable pumps 
SIS Web  Specification manuals for applicable pumps 

Workflow

  1. Gear pump arrives at the dealership specialty repair shop.

  2. A work order is opened or a segment number is assigned to the job.

  3. Any contamination such as mud and dirt, is washed off.

  4. Receiving and inspection reports are filed by the job or segment number and pictures are taken.

  5. Gear pump is scheduled for disassembly.

  6. Gear pumps should be disassembled. After disassembly, fully inspect all piece parts using the required reuse criteria.

  7. As the pump is disassembled, properly place all loose parts into wash baskets.

  8. All new parts and seal kits are ordered.

  9. Parts that are placed into baskets aresentto be washedin a cabinet washer.

  10. Parts that need reconditioning are sent to the correct reconditioning areas. Salvage of a gear pump is limited to touch lapping.

  11. All parts are brought back together at the assembly area.

  12. The pump is reassembled utilizing the Disassembly and Assembly information.

  13. The gear pump is sent to the test bench area for testing.

  14. Gear pump is prepped with secure non-leaking covers or plugs in place.

  15. Gear pump is painted.

  16. The gear pump should now be prepared for storage or shipping.

  17. Gear pump should be placed on a shipping or holding rack.

  18. If delivery and installation are part of the dealer service, a time is scheduled to return and install the pump or motor. If the gear pump is a customer pickup, notify the customer that the pump or motor is completed.

  19. Close the work order and bill the repair.

Receiving

The first thing that a customer should see coming to a dealership is the sign pointing the way to receiving. The sign should indicate hydraulic service receiving. The customer should not have to search for a place to drop off hydraulic components.

Dealership personnel should greet the customer, not the repair technician. The receiving personnel for the customers should be able to off-load the equipment and be able to generate a work order. Work orders should be filled out completely with all available information including the customer complaint and condition of the gear pump.

The receiving area should have adequate means to unload trucks. An overhead crane inside a large overhead door is ideal. A fork truck should be available to off-load pallets from flat bed trucks. Caterpillar does not recommend that the receiving area is located in the pump "clean room". The receiving area should have a good selection of lifting straps and chains. The lifting devices should be dedicated to the receiving area. Dealership personnel should not have to search for equipment to off-load the pumps while the customer waits.

After the gear pump is off-loaded, the gear pump should be placed directly on to an incoming rack. The rack should be able to collect all the oil that could be leaking from the pump. Many pumps could be strapped to wooden pallets when the pumps arrive at the dealership. The pump should be removed from the pallet. Pallets take up too much floor space and leave contamination. The gear pump should have a tag that identifies the work order number and other pertinent information. A tag that can be removed during the power wash and then wired back to the pump is ideal.

Remove Contamination

A dedicated material handler should then transport the gear pump from the receiving area to an initial wash bay. The cleaning room should be overhead-crane accessible. Once the hydraulic component is inside the shop, a fork truck should not be used to move the component. Fork trucks drag debris from the tires into the shop. If a fork truck must be used, the forklift should only go just inside the clean room door. A roll-around cart is recommended to move a gear pump throughout the specialty shop.

The cleaning area should be enclosed to prevent overspray. Utilizing an open area to clean the pumps could carry contamination throughout the rest of the shop. The walls can be steel, glazed concrete, block, or tile for easy cleanup. The cleaning room is intended for use by the rebuild area only. Other parts such as track, Ground Engaging Tool (GET), or greasy engine components should not be brought to the cleaning room from outside. The dual use of the cleaning room is discouraged because of the tracking of dirt into the specialty rebuild area.

The wash bay should be close to the receiving area and dedicated for components. Plug all of the open ports to avoid water from entering the pump. For the best results, Caterpillar recommends a power wash with hot water and detergent. A dedicated wash bay worker or the material handler should wash the pump. The pump should then be transported to the pump repair area. A hoist should be used to retrieve the pump and place the pump on an incoming rack. Depending on the volume of the shop, the rack can be shared with incoming and outgoing pumps. Refer to Special Instruction, SEBF8355, "Cleaning Guide Equipment and Chemical Recommendations Contents" for different modules dedicated to contamination control.

Disassembly

A wall should be used to separate the pump and motor area from the rest of the shop. A key concept of the rebuild facility is to separate the dirty areas from the clean areas, therefore a divider is necessary. An added benefit of the divider is to reduce the noise in the component area. Column mounted jib cranes can be used, but freestanding jib cranes offer greater reach and provide better coverage of the area. The disassembly bench should have the means to handle various sizes of pumps and be able to collect residual oil that must be drained. A sump tray may be used if there is a way to pump out the tray. Worktable drains offer the advantage of making cleaning easier. Refer to Tool Catalog, PECJ0003, "Cat Hand Tools and Shop Supplies", for large-scale tooling required for the disassembly and assembly area. You may also contact Cat Dealer Service Tools for tooling recommendations that are required to handle gear pump Disassembly and Assembly.

A technician should be able to identify incoming pumps by the tag on the pump. The tag should contain the work order number. The work order should be placed on a job board. A hanging file folder works well. A supervisor or a lead person should place the work orders of priority for quick technician retrieval.

The same hoist should be able to move the pump from the incoming rack to the Disassembly and Assembly (D&A) bench. The procedure for disassembling each gear pump may vary between different pumps. Refer to the Disassembly and Assembly procedure for the individual pump. The disassembly procedure can be found on SIS Web or ordered through the Caterpillar Media Logistics System.

Inspection

After the disassembly procedure has been completed, an inspection of the individual pump parts must be conducted. Measurements of the gear diameters and bearing bores should be taken and compared to the specifications in Special Instruction, SEBF8161, "Hydraulic Gear Pumps Used in Transmissions" or Special Instruction, SEBF8073, "Specifications and Reusability for Hydraulic Gear Pumps and Motors". Depending on the pump, one of the Special Instruction documents can be useful in determining the reusability of the components. Be sure to check for stress risers and scratches that can carry contamination. Fine scratches can be hard to see, so hand washing the individual parts in a solvent washer can aid with better quality reuse decisions. The specifications for the individual pumps can be found on SIS Web or ordered through the Caterpillar Media Logistics System. Repair decisions should be made depending on the dealer capability and customer preference. Depending on the situation, a dealer exchange may be a viable option. Minor repairs may only require installing a new seal kit. Major repairs may require ordering new parts.

Parts Ordering

Immediately following the inspection, parts should be ordered. The technician should order parts electronically on a terminal in the pump shop. The parts list can be generated in SIS Web or HIS and ordered with DBS Parts Integrator. Placing the parts list in an e-mail and sending the parts list to the parts department is acceptable, but not the best option. The terminals should be next to an aisle for easy access by all in the pump shop. The terminals should not be over one bay away. A technician should not have to walk to a different shop to order parts. Caterpillar recommends that no more than eight technicians should use one terminal. Depending on the volume of the shop, more terminals may be required.

Parts delivery to the pump shop should be based on a prioritization system. For example, 1 = ASAP. This system should be used on exception basis, if the part is holding up the assembly, and the pump must be assembled right away. 2 = within 30 – 45 minutes. The system would have a standard amount of time to allow for lapping and component wash. By the time the lapping and wash is complete, the parts will be delivered and the pump can be reassembled. A 3 = 24 hours system is for a customer that keeps a spare unit where turn around time is not critical. The exchange can also be for a dealer exchange unit. The key is to manage the time based on particular customer needs. There is no single solution that will fit all needs. Parts delivery of ASAP for every order is not a realistic amount of time. A typical pump repair of 30 minutes or 45 minutes is manageable for the parts department. Another option for some dealers is to automatically order seal kits and all 100% replaceable parts. The dealer will have to do some parts order trending to make this work. Determine the percent of seal kits sold for a particular pump. An automatic parts order can be generated every time a pump part number is entered into the system in the receiving area. If trended properly, a few returns to the parts department should not be an issue.

Parts Cleaning

Once the pump has been disassembled and the parts are determined to be reusable, the parts should be cleaned. Refer to Special Instruction, SEBF8355, "Cleaning Guide Equipment and Chemical Recommendations Reference Manual" for different modules dedicated to contamination control. Caterpillar recommends the use of an automatic method of parts washing. A cabinet washer works well for pump and motor components. The washer should be high pressure with hot water and soap. Maintenance of the wash water is critical for the washer to do the job. Inefficient parts washing is due in large to poor maintenance practices and improper basket loading. Manual cleaning in a solvent washer is not the best use of the technicians time. If an automatic method of parts washing is used, the technician can move on to other tasks. When the parts cleaning cycle has completed, the technician can simply blow dry the parts and begin reassembly.

In-Process Racks/Baskets

In-process racks/baskets could double as automatic parts washing baskets. The parts need to be properly placed to maximize the cleaning efficiency. Proper placement ensures that the parts are protected from damage during the automatic wash cycle. The racks should be placed close to the D&A bench for quick access by the technician. Containers holding the parts should be labeled with the work order number. Parts that are not placed in the storage containers should be wrapped in plastic and marked with the work order number.

Assembly

The Disassembly and Assembly portions of the bench should be separated to ensure cleanliness during the assembly process. Ensure that the Assembly bench is clean from contaminates before assembling a gear pump. Contamination introduced during assembly could cause premature failure to the pump once put into service. Once all reusable parts have been cleaned and new parts have been received, assembly can begin. Refer to the D&A guideline for the respective pump to assemble the pump properly.

Note: Repair technicians should not be involved in any activities after the pump has been assembled. Management of the technicians time is key to a successful operation.

Test

Once the gear pump is assembled, the pump should be tested. Testing a pump verifies the quality and is a benefit and quality assurance measure that should be communicated to the customer. Various tools and fittings should be on hand for quick retrieval. The fluid fittings should be stored in a contamination free bin, rack, or cabinet. The fittings should be organized by type of fitting or grouped by different pump types. Refer to Dealer Service Tool Catalog, NENG2500 for different types of hydraulic Test Benches. Refer to Bench Test Procedure, REHS1832, "Bench Test Procedure for Gear Pumps" to properly test a Caterpillar gear pump.

Paint

All rebuild pumps should be repainted after testing. Painting the pumps shows pride in workmanship and quality. The pump should be cleaned before painting to remove any of the remaining contamination and assembly fluids. Cleaning the pump with hot, soapy, high-pressure water will allow the pump to dry fast. Once the pump is in the paint booth, a person dedicated to the paint booth should prep the pump for paint. Preparing the pump, the ports should be capped or plugged. Also, the machined surfaces and bearings should be protected with tape or grease, and the shaft engagement should be taped off. Allow the pump to dry before handling. After painting, a new tag or sticker is applied to identify this pump as having been repaired and reconditioned. Dealer stickers should be attached to the pump for marketing reasons for future repairs. To track the pump, a tag can be attached to the housing of the gear pump with the date and work order number.

Shipping

The pump should be transported to the shipping area to be placed on an outgoing rack indicating ready for pickup. The best procedure is to keep the incoming pumps separate from the outgoing pumps. The pump should be tagged for quick retrieval. The shipping area should have a large overhead door with an overhead hoist for loading duties. Various lifting devices should be dedicated to the area.

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