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Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
European Union Compliant, CE marked
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 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 Tool Operating Manual.
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" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of 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 warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. 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 and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| Fire hazard |
Safety Warnings
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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| NOTICE |
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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, NENG2500, "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. |
| NOTICE |
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To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information Section
Introduction
The Staking Tool Groups are combination tools used to install and then secure (stake) the sleeve bearing in Tyrone gear pump and motor housings or head assemblies These tool groups can be used when installing sleeve bearings in both iron and aluminum housings.
To install sleeve bearings into iron housings, diameter (A) of guide (6) should be facing downward. Installing sleeve bearings into aluminum housings requires diameter (B) to be facing downward.
Refer to Staking Tool Group Nomenclature Table 1 to identify the tooling and serviceable parts required for this procedure.
Additional Contact Information
For additional product support questions concerning this tool, contact the Cat Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
E-mail: dealerservicetool_hotline@cat.com
Nomenclature
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| Illustration 3 | g02588236 |
Staking Tool Group. | |
| Staking Tool Group Nomenclature | ||||
| Item | FP7 | HP7 | FP8 & HP8 | Description |
| - | 135-7275 | 135-7275 | 130-5946 | Staking Tool Group |
| (1) | 8T-8908 | 8T-8908 | 8T-8908 | Bolt (1/4-20 x 1.0 in) |
| (2) | 6V-7646 | 6V-7646 | 6V-7646 | Washer (1/4 in) |
| (3) | 135-7277 | 135-7277 | 130-5947 | Cap |
| (4) | 125-8274 | 125-8274 | 125-8274 | O-ring Seal |
| (5) | 129-1875 | 129-1875 | 129-1875 | Staking Leg (2 Qty) |
| (6) | 135-7268 | 135-7268 | 129-1872 | Guide |
| (7) | 135-7276 | 135-7276 | 129-1874 | Sleeve |
| (8) | 135-7269 | 135-7269 | 129-1873 | Driver |
| (9) | - | 147-9658 | - | Shim |
Operation Section
The following procedure is used for Tyrone FP7, FP8, HP7, and HP8 Gear Pumps and Motors. This procedure requires a hydraulic press capable of attaining 4.5 t (5 tons) of force.
Always refer to the ""Nomenclature" " section for correct part numbers and placement, depending on pump style.
Note: Only use 147-9658 Shim (9) for HP7 (Aluminum housing pumps and motors).
Staking Procedure
- Assemble correct guide (6), driver (8), staking legs (5) and, if required, Shim (9) into sleeve (7) .
- For FP7 and FP8 iron housings (E), position guide (6) with diameter (A) down, as shown. This position installs the sleeve bearing slightly below the surface of housing (E) .
- For HP7 aluminum housings (E), position guide (6) with diameter (B) down, as shown. Be sure to install Shim (9). This position installs sleeve bearing (F) approximately 5.70 mm (.225 inch) above the surface of the housing.
Show/hide table
Illustration 4 g02588296
(E) FP7 and FP8 Iron Housings. (6) Guide With Diameter (A) Down.
- For HP8 aluminum housings (E), position guide (6) with diameter (B) down, as shown. Do not use shim (9). This position installs sleeve bearing (F) approximately 8.0 mm (.31 inch) above the surface of the housing.
- Install bolt (1), washer (2), and cap (3) to hold the staking tool together as a unit.
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| Illustration 5 | g02588317 |
(E) HP7 and HP8 Aluminum Housings. (6) Guide With Diameter (B) Down. (9) Shim (For HP7 housing only). | |
- Install the proper sleeve bearing (F) over diameter (A) or (B), depending on housing style. The sleeve bearing should be seated against the shoulder of guide (6) .
Note: Install the bolt finger tight.
- Carefully position the pump or motor housing in a hydraulic press capable of attaining 4.5 t (5 tons) of force.
| NOTICE |
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When positioning the pump/motor housing (E) in a hydraulic press, make sure it is level. If the sleeve bearing bore is not aligned correctly, the housing and/or the sleeve bearing can be damaged beyond repair when the sleeve bearing is pressed into the housing. |
- Place the staking tool and sleeve bearing (F) on housing (E) and align the sleeve bearing to the housing bore.
- Remove bolt (1) and washer (2) from the top of the staking tool guide stem.
| NOTICE |
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When positioning tooling on housing (E) make sure staking legs (5) are in alignment with staking grooves (10) in the housing. If they are not aligned, the housing will be damaged. |
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| Illustration 6 | g02588337 |
(11) Bore of Housing (Bottom View, Looking Up). (5) Staking Legs. (10) Staking Grooves. (C) Staking legs correctly aligned. (D) Staking legs not aligned. | |
- Use hydraulic press (12) to push the staking tool and sleeve bearing (F) into the housing bore just until sleeve (7) contacts the surface of pump or motor housing (E). Do not apply more force than is required.
- Retract the hydraulic press. Remove the cap from the staking tool. Extend the hydraulic press to contact the upper guide stem end of driver (8) .
Note: The hydraulic press must not contact the upper guide stem during this step. The guide stem should be recessed in the cap, as shown.
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| Illustration 7 | g02588364 |
(7) Sleeve. (12) Hydraulic Press. (E) Pump or Motor Housing. | |
- Use the hydraulic press to push driver (8) down until the hydraulic press is even with the top surface of sleeve (7). Do not apply more force than is required. Sleeve bearing (6) is now staked (G) into pump or motor housing (E) .
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| Illustration 8 | g02588367 |
(7) Sleeve. (8) Driver. (12) Hydraulic Press. (E) Pump or Motor Housing. | |
- Retract the hydraulic press. Place cap (3) on the staking tool. Install bolt (1) and washer (2) through cap and thread into upper guide stem. Use a wrench to tighten the bolt until driver (8) releases the pressure on the staking legs.
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| Illustration 9 | g02588376 |
(6) Sleeve Bearing. (7) Sleeve. (8) Driver. (E) Pump or Motor Housing. (G) Stake. | |
- Carefully remove the staking tool from the sleeve bearing. Some twisting or back and forth motion may be required to remove the staking tool.
| NOTICE |
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Use of air powered or impact tools can damage the threads of the bolt and/or upper guide stem. Only use a hand wrench when tightening the bolt to release pressure on the staking legs. |
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| Illustration 10 | g02588396 |
(1) Bolt. (2) Washer. (3) Cap. (8) Driver. | |
- Inspect the pump or motor housing to make sure sleeve bearing staking (G) is complete and properly located within the housing bore.
- Make sure sleeve bearing (H) is properly positioned relative to the top surface of the pump or motor housing, depending on the model.
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| Illustration 11 | g02588398 |
(G) Sleeve Bearing Stakes. | |
Note: For more information on correct sleeve bearing placement in the bore, refer to Steps 1.a, 1.b, and 1.c in this manual.
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| Illustration 12 | g02588400 |
(H) Sleeve Bearing. | |
Maintenance Section
Inspection, Lubrication, and Storage
To prolong the service life of this tooling, follow these guidelines.
- Inspect prior to each use for nicks, burrs, dents, cracks, or worn parts. If damage is found, discontinue use until replacement parts are available.
- Clean bolt threads and lightly lubricate with a high pressure lubricant.
- After each use, disassemble tooling and wipe down with a clean cloth. Store organized tooling in a storage case in a clean, dry location.