Specifications and Reusability for Hydraulic Gear Pumps and Motors (Groups 1, 2, and 3) {5061, 5073} Caterpillar

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Introduction

Table 1

Revision	Summary of Changes in SEBF9141
23	Updated Effectivity.
22	Updated Effectivity.
21	Updated Effectivity.
20	Updated Effectivity.

© 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 Caterpillardealers and customers to benefit from cost reductions. Every effort has been made in 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 not 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 and motor parts used on Caterpillar machines. Specifically, the guideline shows illustrations of gear pump and motor parts which cannot be used again without salvage operations. All specification previously included in Special Instructions, SEBF8073, "Specifications and Reusability for Hydraulic Gear Pumps and Motors" are now incorporated into this guideline.

Parts that can be used again according to this guideline can be expected to give normal performance until the next overhaul.

Important Safety Information

Illustration 1	g02139237

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.

Illustration 2	g01032906

The following is the meaning of this safety alert symbol:

• Pay attention!

• Become Alert!

• Your safety is involved

The message that appears under the warning explains the hazard. The message will be written or pictorially shown.

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. Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used during the procedure. Ensure that all personnel around the machine are safe. 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.

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

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.

Show/hide table

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.

• Iron body pumps will cause a damaged look to the gear tooth tips during break-in. This damaged look is caused by the gear tooth tips contacting the rough iron housing of the pump. Along with the damaged look, the tooth tips will also have a lip or burr on the trailing edge. The lip or burr is also caused by contact between the tooth tip and the iron housing.

• Do not install a part again if this guideline shows that the part cannot be used again.

• Do not 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 "cause and effect" relation to other parts. Generally, failure wear or damage to one part can affect the performance of connected parts. Here is an illustration of how one problem can be an indication of the source of a larger, future problem. There is light wear on the bearing diameter of the gear shaft. The wear is from contaminants which are embedded in the Teflon material that coats 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 failure.

• Most of the illustrations in this guideline are of pumps and not motors. Pumps have a different purpose than motors, but wear and damage characteristics are similar in both. Normally, making salvage procedures the same in both, unless other procedures are given.

• Specifications needed to recondition gear type hydraulic pumps and motors are given in the "Service Manual" and in this guideline.

• The parts in hydraulic pumps and motors 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 permit. Be sure to test all rebuilt pumps for acceptable performance. Refer to Special Instruction, REHS1832, "Bench Test Procedure for Gear Pumps" and the "Service Manual" for test specifications

• Flame Spray is an acceptable method of restoring a surface to the original size. Each step in the procedure is critical in achieving the desired coating bond and the surface finish. Refer to Special Instruction, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components". The guide provides recommendations for Flame Spray and also contains applications for various parts that use Flame Spray.

References

Table 2

Media Number	Title
SEBF8073	"Specifications and Reusability for Hydraulic Gear Pumps and Motors"
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"
SEBF2110	"Thermal Spray Procedures for Pump Drive Gear Inside Diameter"
SEBF2129	"Thermal Spray Procedures for Tyrone Drive Shaft (Pump Gear)"
SEBF2156	"Thermal Spray Procedures for Gear Shafts for Gear Pumps"
REHS1832	"Bench Test Procedure for Gear Pumps"
SEHS8428	"Removing and Installing Bushings and Pressure Plates in Hydraulic Gear Pumps"
NENG2500	"Dealer Service Tool Catalog"
PEGJ0075	"Loctite ® Cross Reference List for Cat Part Numbers"
SEBF9140	"Specifications and Reusability for Hydraulic Gear Pumps and Motors (Groups 9, 10, and 11)"
SEBF9173	"Specifications and Reusability for Hydraulic Gear Pumps and Motors (Groups 4, 5, and 6)"

Tooling and Equipment

Table 3

Part Number	Part Description
4C-9507	Retaining Compound
6V-6050	Ultrasonic Cleaner Group
7B-0337	Surface Plate
9B-3500	Insert Kit
9B-3700	Insert Kit
Loctite 97453	Loctite ® Fixmaster Epoxy
Loctite AC-4368	Releasing Agent

Pump and Motor Identification Chart

This guideline is for gear pump and motor Groups 1, 2, and 3. Refer to specifications in Table 4 to verify your pump group. Once you have verified your pump group, use Table 4 to choose the correct document number for your pump group.

Illustration 3	g01438510
Measurements are taken from these locations. (1) Number of gear teeth (2) Gear diameter (3) Journal diameter

Table 4

Pump and Motor Identification Chart
Group	Journal Diameter mm(inches)	Gear Diameter mm(inches)	Number of Gear Teeth	Pressure Plate Thickness mm(inches)	Bushing Style	Document Number
1	44.45 mm (1.75 inch)	77.22 mm (3.04 inch)	10	10.92 mm (0.43 inch)	Flush	SEBF9141
2	31.75 mm (1.25 inch)	60.96 mm (2.40 inch)	10	9.65 mm (0.38 inch)	Flush
3	39.62 mm (1.56 inch)	77.22 mm (3.04 inch)	10	10.92 mm (0.43 inch)	Flush
4	44.45 mm (1.75 inch)	77.22 mm (3.04 inch)	10	7.87 mm (0.31 inch)	Extended	SEBF9173
5	47.50 mm (1.87 inch)	91.44 mm (3.60 inch)	10	7.87 mm (0.31 inch)	Extended
6	47.50 mm (1.87 inch)	91.44 mm (3.60 inch)	10	10.67 mm (0.42 inch)	Flush
7	15.75 mm (0.62 inch)	30.99 mm (1.22 inch)	10	Bushing Block		-
8	22.10 mm (0.87 inch)	44.70 mm (1.76 inch)	10	Bushing Block
9	31.75 mm (1.25 inch)1.25	64.52 mm (2.54 inch)	8	6.60 mm (0.26 inch)	Extended	SEBF9140
10	39.624 mm (1.56 inch)	80.77 mm (3.18 inch)	8	7.87 mm (0.31 inch)	Extended
11	31.75 mm (1.25 inch)	60.96 mm (2.40 inch)	10	6.60 mm (0.26 inch)	Extended

Flange, Plate, and Body Assemblies

Nomenclature

Illustration 4	g01517398
Flange assembly for Group 1 (4) Body Face (5) Dowel Holes (6) Bushings

Illustration 5	g01517402
Flange assembly for Group 2 (4) Body Face (5) Dowel Holes (6) Bushings

Illustration 6	g01517406
Flange assembly for Group 3 (4) Body face (5) Dowel holes (6) Bushings

Illustration 7	g01517410
Body assembly for Group 1 (7) Gear Bore (8) Bushing (9) Seal Groove

Illustration 8	g01517414
Body assembly for Group 2 (7) Gear Bore (8) Bushing (9) Seal Groove

Illustration 9	g01517423
Body assembly for Group 3 (7) Gear Bore (8) Bushing (9) Seal Groove

Cleaning Procedure

Remove lip seals and remove weep hole plugs first. Wash the pump flanges, plates, and bodies with clean solvent. Use petroleum-based solvent. Be sure to clean inner surfaces. Clean weep hole plugs and seal drain passages. Remove all sealant from seal grooves. The seal will not seat correctly if the grooves are not cleaned properly. If sealant cannot be removed with the solvent and a brush, use glass beads. Use beads of 80 to 150 micron (size 10) with 585 ± 35 kPa (85 ± 5 psi). Early flanges were equipped with metallic seal drain valves, which are made of Viton material. Before installing a new seal drain valve, a steel sleeve must be installed in the drain valve passage first.

Inspection Procedure

Mounting Face

Illustration 10	g01420737

Illustration 11	g01508722
Fretting on the mounting face of the pump can be an indication that the face is bent. Take two measurements on the face of the pump. One measurement near the pilot diameter (X) and one measurement near the mounting bolt hole (Y), as shown in Illustration 11.

USE AGAIN

The flange can be used again if the difference between the two measurements is less than 0.5 mm (0.02 inch).

Seal Bore

Illustration 12	g03424129
Light scratches in the seal bore

USE AGAIN

Note: Apply 4C-9507 Retaining Compound around the joint between the seal case and the bore when you install a new seal. This procedure will prevent seal to bore leakage.

Illustration 13	g03424132
Damage in the seal bore

USE AGAIN

The seal bore can be repaired. Refer to Section "Procedure to Salvage Seal Bore" in this document.

Bushing

The bushings have a bronze layer which is a porous material. The Teflon overlay is mated with the pores during manufacturing by pushing the two materials together. Wear in the load zone of the bushing will cause more of the bronze to appear. The bushing can still be used again because the surface is a mix of bronze and Teflon. The bronze also shows through when the Teflon in the non-load zone of the bushing becomes worn. The surface will appear rough but the bushing can be used again. Refer to Illustration 14.

USE AGAIN

Illustration 14	g01420762
An example of normal bushing wear. The bronze is showing through the Teflon.

USE AGAIN

Illustration 15	g01420764
A scored and spalled bushing

DO NOT USE AGAIN

Note: Bushings in Illustrations 14 and 15 were cut to allow the condition to be seen.

Illustration 16	g01516600
An example of flush mounted bushings with two different conditions. (10) Peeled Teflon surface (11) Severely spun bushing

DO NOT USE AGAIN

Illustration 17	g01516596
An example of flush mounted bushings that are in good condition. Pumps in Groups 1, 2, and 3 have flush mounted bearings.

USE AGAIN

Note: These illustrations are used for showing different conditions and the following illustrations also show raised bushings. None of the pumps in this document have raised bushings. Refer to Illustrations 18 and 19.

Illustration 18	g03426796
Typical example of the Teflon peeling on the inside diameter of the bushing.

DO NOT USE AGAIN

Illustration 19	g03426791
An example of a bushing that has turned in the bore.

DO NOT USE AGAIN

Inspect the bushing bore for out of round after the bushing is removed. If the bushing bore is out of round by more than 0.05 mm (0.002 inch), do not use the casting again. A bushing bore that is out of round is an indication that the gear track is too deep. The pump housing must then be replaced.

Bushings are installed with the seam in line with the dowel pin holes. The seams should be 180 degrees away from each other.

The installation of new bushings will affect the efficiency of the unit. When installing new bushings, the gears will move to a new position. The tips of the gear teeth will move away from the worn gear track. This action causes the pump efficiency to go down. Pump testing is required after all pump repairs to check for correct pump efficiency.

Table 5 lists the tooling used to remove and install the bearings. Use of the bushing installer group will install the bushings to the correct depth and properly stake the bushing in place. Refer to Special Instruction, SEHS8428, "Removing and Installing Bushings and Pressure Plates in Hydraulic Gear Pumps" for detailed instructions on replacing the bushings. The tool chart lists tooling for either single or tandem version pumps.

Table 5

Tooling
Pump Group	Bushing Removal Tool	Pressure Plate Removal Group	Bushing Installer Group
1	4C-9630	-	135-7275
2	8T-9137	8T-0875	8T-0880
3	8T-9128	8T-9134	8T-9133
4	4C-9630	-	135-7275
5	4C-9631	-	130-5946
6	4C-9631	-	130-5946
7	Bushing Block Design
8
9	8T-9137	8T-0875	8T-0880
10	8T-9128	8T-9134	8T-9133
11	8T-9137	8T-0875	8T-0880

Illustration 20	g01516605
Bushing installer group for pumps in Group 1.

Illustration 21	g01524613
Bushing installer group for pumps in Groups 2 and 3.

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, there is an issue with the bushing. More than likely, the bushings were not staked in place properly. Remove the bushing and install a new bushing. Repeat the process until the plug gauge slides through the bushing freely.

Illustration 22	g01508987
Plug Gauge. Dimensions shown are in inches.

Table 6

Plug Gauge Dimensions
Pump and Motor GP number	Dimension A
1	44.63 mm (1.757 inch)
2	31.81 mm (1.252 inch)
3	39.70 mm (1.563 inch)

Gear Track

The maximum allowable depth in the gear track for an aluminum pump body is 0.38 mm (0.015 inch) on the low-pressure side of the unit.

Illustration 23	g01513237
(A) This area is the high-pressure side of the pump. Gear track is not allowed in this area. (B) Maximum area of gear track allowed in the housing. (C) This area is the low-pressure side of the pump. Normal gear track area.

The maximum allowable depth in the gear track for an iron pump body is 0.28 mm (0.011 inch) on the low-pressure side of the unit.

Normal gear track depth is 0.15 mm (0.006 inch) to 0.20 mm (0.008 inch).

Table 7

Housing Gear Bore Diameter
Pump and Motor Group Number	Maximum Gear Bore Diameter
1	77.44 mm (3.049 inch)
2	61.06 mm (2.404 inch)
3	77.42 mm (3.048 inch)

Illustration 24	g01518573
Normal wear for iron body pumps (15) Suction Port (16) Body pre-track (17) Gear Track

USE AGAIN

Note: Body pre-track (16) is from the machining process during manufacturing. Gear Track wear (17) is normal after break-in test is performed. Discard the pump if the gear track wear (17) measures deeper than 0.28 mm (0.011 inch) in iron body pumps or 0.38 mm (0.015 inch) in aluminum body pumps. Refer to Illustration 24.

Illustration 25	g01517914
The back cut in the gear bore is found on a few of the Group 1 pumps.

USE AGAIN

Note: The back cut in the gear bore is on the outlet side of the pump. Refer to Illustration 25.

Illustration 26	g01422124
A burr on the edge of the gear track.

USE AGAIN

Illustration 27	g01516649
Damage that was caused by foreign material.

USE AGAIN

Erosion, or damage on the low-pressure side of the gear track in Illustration 27 will not affect performance. If the erosion or damage has extended to the high-pressure side of the pump, do not reuse the pump. Extended damage will result in a loss in efficiency. The loss in efficiency cannot be determined without testing the pump. Test these castings after assembly to be sure that the level of efficiency is acceptable. Pumps with this condition will run at a higher noise level.

Note: The damage is on the low-pressure side. If the damage is extended to the high-pressure side of the pump, do not reuse the pump.

Seal Groove

Illustration 28	g03424145
Sealant in the seal groove

USE AGAIN

After the sealant is removed, refer to Section "Cleaning Procedure" for details.

Illustration 29	g01422129
Damaged seal groove

DO NOT USE AGAIN

Illustration 30	g01420928
Damaged seal face

DO NOT USE AGAIN

Illustration 31	g01422134
Damage across the O-ring seal area of the seal face.

DO NOT USE AGAIN

Note: Similar damage across the O-ring groove can cause leakage, as can tool chatter in the bottom of the O-ring groove. Do not reuse the part if the part has either condition. Refer to Illustration 31.

Threads

If the bolt cannot be tightened to the correct torque specifications, the threaded hole is possibly damaged.

Illustration 32	g01516655
Pieces of aluminum in the threads of this bolt are an indication that the threaded hole in the pump is damaged.

USE AGAIN

Remove aluminum from the bolt with a wire brush.

Illustration 33	g03424150
Threaded hole in the pump body is damaged.

USE AGAIN

Use again after repairing the threads with an insert from 9S-3500 (UNF) Master Repair Insert Kit or 9S-3700 (UNC) Master Repair Insert Kit.

Miscellaneous

Illustration 34	g01422148
Side clearance can be felt in the dowel hole.

DO NOT USE AGAIN

Note: Do not reuse the mating piece.

Illustration 35	g01510053
Crack in the casting flange

DO NOT USE AGAIN

Illustration 36	g01510075
Crack in the casting flange

DO NOT USE AGAIN

Illustration 37	g01510080
Crack in the casting flange

DO NOT USE AGAIN

Illustration 38	g01510104
Crack in the gear body

DO NOT USE AGAIN

Illustration 39	g01422157
Crack in the seal area of the port

DO NOT USE AGAIN

Procedure to Salvage Seal Bore

Most of the damage in the pump flange, plate, and body assembly are either acceptable as is or not at all. Generally, if the part is not usable as is, salvage is not practical, except if the damage is seal bore damage.

Note: Follow the manufacturer directions carefully in the use of Loctite products. Refer to Special Publications, PEGJ0075, "Loctite © Cross Reference List for Cat Part Numbers" or http://www.useloctite.com/caterpillar.

Use the following procedure to salvage the seal bores.

1. Remove any raised metal in the bore with 180 grit crocus cloth.
   Show/hide table

   Illustration 40	g03424152
   Be sure that the bore is clean and dry.

2. Make sure that the bore is free of oil and dirt. Use cleaner or solvent to remove oil. Also, make sure that the seal bore is dry.
   Show/hide table

   Illustration 41	g01422160
   Put Loctite AC-4368 releasing agent on the outside diameter of the seal case.

3. When the part is at room temperature 21 °C (70 °F), put a layer of Loctite AC-4368 releasing agent on the outside diameter of the seal cases.
   Show/hide table

   Illustration 42	g03424154

4. Apply an application of Loctite 97453 epoxy on the damaged area. Be careful not to get any Loctite 97453 into the seal drain passage. Refer to Illustration 42.

5. Install the seal in the bore. Do not install the flange assembly for 2 hours.

Gear Shaft

Nomenclature

Illustration 43	g03351159
Gear shaft nomenclature. (18) Tooth profile (19) Tooth face (20) Spline (21) Seal area (22) Bearing areas

Cleaning Procedure

Wash gears with a clean solvent that is made from petroleum. Clean gears carefully to prevent damaging the bearing areas. Removing any discoloration from the gears is not necessary. Oil caused the discoloration and is acceptable.

Inspection Procedure

Shaft Seal Area

Illustration 44	g03424380
Grooves in the seal area can be felt with a fingernail.

USE AGAIN

Use the shaft again after the seal area is salvaged according to the correct procedure. Refer to Section "Procedure to Salvage Shaft Seal Area".

Illustration 45	g03424383
Corrosion in the seal area

USE AGAIN

Use the shaft again after the seal area is salvaged according to the correct procedure. Refer to Section "Procedure to Salvage Shaft Seal Area".

Illustration 46	g03424386
Splines show signs of interference.

USE AGAIN

Use the shaft again after adjusting the shaft installation to prevent interference.

Note: If the splines are twisted on a shaft, do not use the shaft again.

Illustration 47	g03424389
Fretting in the splines can be felt with a fingernail.

DO NOT USE AGAIN

Illustration 48	g03426805
Light spline damage

USE AGAIN

Illustration 49	g03424402
Heavy spline damage

DO NOT USE AGAIN

Journal Area

Illustration 50	g03424751
The journal of the shaft shows wear that was caused by contaminants.

USE AGAIN

Use 400 grit crocus cloth and motor oil to remove the scratches.

Note: Metal spraying the journal area of the shaft is not necessary.

Illustration 51	g03424778
Corrosion in the journal area and the tooth face

USE AGAIN

Use 400 grit crocus cloth and motor oil to remove the scratches from the shaft.

Note: If corrosion has caused pitting in the shaft, do not use the part again.

When reconditioning the shaft journal, install the shaft in a lathe for proper operation. Use a flat file behind the crocus cloth to polish the journal of the shaft and the tooth face area. Refer to Illustration 51 and Illustration 52.

Tooth Face

Illustration 52	g01510356
Scratches on the face of the gear tooth.

Illustration 53	g01510357

USE AGAIN

Use the shaft again after most of the scratches and all of the burrs are removed with 400 grit crocus cloth and motor oil. Install the shaft in a lathe for the correct procedure. Use a flat file behind a piece of crocus cloth to polish tooth face area.

Note: The area between the journal and the tooth face valley must not contain any scratches. Refer to Illustration 53.

Tooth Profile

Illustration 54	g01421004
Heavy damage on a tooth profile

DO NOT USE AGAIN

Illustration 55	g01516677
Lip on trailing edge of tooth profile

USE AGAIN

Note: The lip on the edge of the tooth tip was caused by the break-in test. This lip is normal in iron housing pumps. Aluminum housing pumps will not cause this type of wear because aluminum will yield to the hardness of the tooth tip. The next three images show normal tooth tip wear in iron housing pumps.

Illustration 56	g01516695
A lip on the trailing edge of the tooth. This feature is normal for iron body pumps.

USE AGAIN

Illustration 57	g01516700
Rough tooth tip edge

USE AGAIN

Note: The rippled look of the tooth tip is normal in iron housing pumps. This rippled look is caused by tooth tip contact with the bore of the iron housing.

Illustration 58	g01516706
Rough tooth tip edge and a lip on the trailing edge of tooth tip

USE AGAIN

Note: Illustration 58 shows the rippled look on the tooth tip and the lip caused by contact between the tooth tip and bore of iron housing pumps.

Illustration 59	g01422182
(23) Tooth tip wear

USE AGAIN

Use again if material wear from tip is less than 0.25 mm (0.01 inch).

Note: Significant tooth tip wear only occurs in iron body pumps.

Table 8

Minimum Allowable Diameter for Gear Tips
Pump and Motor Group Number	New Diameter	Min. Diameter Allowed
1	77.32 mm (3.044 inch)	77.09 mm (3.035 inch)
2	60.96 mm (2.40 inch)	60.91 mm (2.398 inch)
3	77.34 mm (3.045 inch)	77.27 mm (3.042 inch)

Illustration 60	g01421091
Light wear on tooth profile

USE AGAIN

Illustration 61	g01421093
Heavy wear on the tooth profile

DO NOT USE AGAIN

Illustration 62	g01516712
Heavy wear in the profile of the gear teeth

DO NOT USE AGAIN

Illustration 63	g01516733
Tooth relief for Group 1 pumps and motors

USE AGAIN

Note: Do not confuse tooth relief with tooth profile wear. Tooth relief gears will only be found on Group 1 pumps and motors. Not all Group 1 pumps and motors use the tooth relief gears.

Illustration 64	g01440734
Showing tooth relief at a different angle. Tooth relief only pertains to Group 1.

USE AGAIN

Note: Do not confuse tooth relief with tooth profile wear. Tooth relief gears will only be found on Group 1 pumps and motors. Not all Group 1 pumps and motors use the tooth relief gears.

Shaft

Illustration 65	g01516777
Light damage to the end of the shaft

USE AGAIN

Procedure to Salvage Shaft Seal Area

Grooves in the seal area that can be felt with a fingernail can be removed. Removing the grooves will make the part usable again. Refer to Illustration 65.

Note: Follow the Flame Spray manufacturer directions carefully in the application of Flame Spray to the shaft seal area.

The procedure to salvage shaft seal area is as follows:

1. Measure the outside diameter of the shaft at the seal area along with the shoulder radius if present. Make a note of each dimension.

2. For the correct Flame Spray procedures, refer to Special Instruction, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components". The guideline also contains applications for various parts that use Flame Spray.

3. Grind the seal area to the diameter measured in step to 0.05 mm (0.002 inch). The surface finish must be 0.40 to 0.80 µm (16 to 32 microinch). The wheel radius must be the same or greater than the shoulder radius measured in Step 1.

Illustration 66	g01516780
The seal area has been flame sprayed.

Pressure Plate

Nomenclature

Illustration 67	g01517964
Pressure plate nomenclature. Refer to Table 9 for dimensions. (24) Bronze face (25) Bearing bore diameter

Illustration 68	g01517966
Pressure plate nomenclature. Refer to Table 9 for dimensions. (26) Bearing bore diameter (27) Backup ring groove

Cleaning Procedure

Wash pressure plates with clean petroleum-based solvent. Be especially careful not to damage the bronze face during the procedure. Removing oil discoloration is not necessary. Remove carbon deposits with the 6V-6050 Ultrasonic Cleaner Group.

Inspection Procedure

Table 9

Pressure Plate Measurements
Pump and Motor Group Number	Minimum Pressure Plate Thickness
1	10.82 mm (0.426 inch)
2	9.70 mm (0.382 inch)
3	7.89 mm (0.311 inch)

Illustration 69	g03393490
Carbon deposits on the bronze face

Illustration 70	g01422198
Measure pressure plate flatness.

USE AGAIN

Use the plate again after the carbon is removed by ultrasonic cleaning. Small surface marks on the bronze face can be removed by a procedure known as "touch lapping". To touch lap, cover surface plate 7B-0337 with 180 grit crocus cloth. Wet the cloth thoroughly with clean petroleum-based solvent. Place the part that is being touch lapped on the wet cloth with the surface that is being touch lapped facing down on the cloth. Move the part in the shape of the number "8". Wash the part in clean solvent after touch lapping. Allow the part to dry at room temperature.

Be sure that the plate is not bent. Check thickness according to Table 9. Check for pressure plate flatness by holding the two plates together with the bronze side facing each other. If a 0.18 mm (0.007 inch) feeler gauge fits between the two plates, the plates are no longer acceptable.

Illustration 71	g03424785
Scratches in the pressure plate

USE AGAIN

Illustration 72	g01422201
Step in the pressure plate

USE AGAIN

Use again if the step can be removed by touch lapping and if the plate has an acceptable thickness according to Table 9.

Illustration 73	g01516920
Erosion, near the pressure equalization chamfer

USE AGAIN

Illustration 74	g01421108
Smearing on the bronze face

DO NOT USE AGAIN

Illustration 75	g01421110
Pitting on the pressure plate

USE AGAIN

Use again if the plate has an acceptable thickness according to Table 9.

Miscellaneous Parts

Cleaning Procedure

Clean miscellaneous parts such as bushing supports, couplings, isolation plates, and support rings with clean petroleum-based solvent.

Note: Never reuse old seals. Always use new seals.

Inspection Procedure

Illustration 76	g03426810
Damaged coupling

USE AGAIN

Reuse if 75 percent of each spline is still in acceptable condition.

Illustration 77	g03426816
The tip of the isolation plate is broken. Isolation plates are not found on all pumps. Some of the Group 2 pumps and motors have isolation plates. The pump and motor part numbers for Group 2 are 145-3996, 145-3997, 186-5430, 188-3304, 207-8611, 212-5948, 223-3750, 223-3751, 223-3753, 231-6587, 237-7419, and 289-3530.

DO NOT USE AGAIN

Illustration 78	g03426829
The isolation plate was damaged during assembly. Isolation plates are not found on all pumps and motors. Some of the Group 2 pumps and motors have isolation plates. The pump and motor part numbers for Group 2 are 145-3996, 145-3997, 186-5430, 188-3304, 207-8611, 212-5948, 223-3750, 223-3751, 223-3753, 231-6587, 237-7419, and 289-3530.

DO NOT USE AGAIN

Test Procedure

For the correct break-in procedure, refer to Bench Test Procedure, REHS1832, "Bench Test Procedure for Gear Pumps".