Replacement of Implement Pump with Gear Pump{5055, 5084} Caterpillar

Replacement of Implement Pump with Gear Pump{5055, 5084} [REHS1350]

HYDRAULIC SYSTEM

PUMP GP

Replacement of Implement Pump with Gear Pump{5055, 5084}

1.1. Introduction

2.1. Safety

3.1. References

4.1. Necessary Parts

5.1. Required Tools

6.1. Machine Preparation

7.1. Removal Procedure for Machines with the 9T-1080 Vane Pump

8.1. Removal Procedure for Machines with the 174-8147 Vane Pump

9.1. Installation Procedure for the New Gear Pump and the New Hydraulic Lines

10.1. Machine Preparation for Operation

11.1. Standard Torque for Fasteners

Track-Type Tractor:
D10R (S/N: 3KR1-UP)

Introduction

The hydraulic implement gear pump is now available for special applications. This special instruction provides the procedures to replace the current vane pump with a gear pump.

After installation is complete, prepare the machine for service. Follow the procedure in the Operation and Maintenance Manual for your machine.

Do not attempt any procedure in this Special Instruction or order any parts until you read the information and you understand the information.

Safety

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Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

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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, and the 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.

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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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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 brake system.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide"for tools and supplies to collect and contain fluids in AVSpare machines. Dispose of all fluids according to local regulations.

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NOTICE

Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

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NOTICE

Maintain the oil in the hydraulic system at the correct level to prevent pump cavitation.

References

Reference: Contamination Control Guidelines, SEBF8456, "(D7-D11) Track-Type Tractor"

Reference: Service Manual, RENR2055, "D10R Track-Type Tractor"

Reference: Operation and Maintenance Manual, SEBU6969, "D10R Track-Type Tractor"

Reference: Disassembly and Assembly, SENR8426, "D10R Track-Type Tractor Machine Systems"

Reference: Service Magazine, SEPD0554 11 December, "Elimination of the Air Purge Valve Improves the System Reliability"

Necessary Parts

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Table 1
Necessary Parts
Item	Qty	Part Number	Description	Former Part Number
1	1	3K-0360	O-Ring Seal
2	1	9S-4185	Plug	8M-0505 ⁽¹⁾
3	1	9T-9840	Gear Pump	9T-1080 or 174-8147 ⁽²⁾
4	1	5F-3106	O-Ring Seal
5	1	6V-8400	O-Ring Seal
6	1	6V-9006	Elbow	148-8334 ⁽³⁾
7	1	2S-4078	O-Ring Seal
8	1	8E-1144	Hose As	9W-2252
9	1	6Y-8456	Elbow	9G-6242
10	2	1P-3705	Rectangular Seal
11	1	127-8930	Hose As	117-7425
12	1	8E-0381	Hose As	7G-2387
13	1	127-8929	Hose As	7G-2390
14	1	194-1593	Hose As
15	1	174-6052	Bracket
16	1	8T-4896	Hard Washer
17	1	1S-1015	Clip
18	1	4L-6454	Bolt
19	1	4J-0524	Seal
20	1	9S-6130	Plug
21	1	2S-4078	Seal

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^( 1 )	The 9S-4185 Plug will be used in place of the 8M-0505 Connector .
^( 2 )	The 9T-9840 Gear Pump will be used in place of the 9T-1080 Vane Pump or the 174-8147 Vane Pump .
^( 3 )	The 6V-9006 Elbow will be used in place of the 8T-3611 Connector .

Required Tools

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	1
A	8S-9906	Ratchet Hoist	1

Machine Preparation

Move the machine to a smooth horizontal location. Move away from machines that are working. Move away from personnel. Lower implements to the ground.

Permit only one operator on the machine. Keep all other personnel away from the machine or keep personnel in the view of the operator.

Engage the parking brake.

Stop the engine.

Use the pressure purge valve that is on the top of the hydraulic tank to release the pressure in the tank.

Move the hydraulic control levers to all positions in order to release the pressure in the hydraulic system. Move the control lever to the FLOAT position.
Note: Make sure that all of the hydraulic pressure is released before any fitting, any hose, or any component is loosened, tightened, removed or adjusted.

The pressure in the system has now been released and lines or components can be removed.

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Illustration 1	g00906129

Drain the hydraulic tank at the drain port. Collect the hydraulic oil in a suitable container.

Clean the inside of hydraulic tank. If dirt and/or metallic particles are present, clean the cylinders and other components.
Note: You can separate the halves of the tank in order to clean the tank or you can remove the filter and reach into the tank in order to clean the tank.

Remove the floorplate that is in the operator compartment.

Removal Procedure for Machines with the 9T-1080 Vane Pump

Note: The suction hose assembly is connected to the lower side of the 9T-1080 Vane Pump . This pump is normally found on D10R (S/N: 3KR1-1461) Track-Type Tractors. If your machine does not have a 9T-1080 Vane Pump see ""Removal Procedure for Machines with the 174-8147 Vane Pump " ".

Note: To make identifying hoses easier, most of the graphics are shown while the vane pump is still installed.

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Illustration 2	g00904649
Typical Implement Pump

Disconnect hose assembly (C), hose assembly (D), and hose assembly (E) .

Remove the four mounting bolts that hold pressure control valve (B) to the pump. Remove pressure control valve (B) .

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Illustration 3	g00905022
Typical Implement Pump

Disconnect hose assembly (K) from elbow (H) by removing four bolts (J) .

Remove four bolts (F) from elbow (G). Tie the hoses out of the way in order to remove the implement pump.

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Illustration 4	g00899401
Callout (Q) is for future reference.

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Illustration 5	g00607518

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Illustration 6	g00904890
Typical Implement Pump

Remove hose assembly (R). Remove connector assembly (P) from hose assembly (N) .

Attach Tooling (A) to the cab ceiling and implement pump (M), as shown.

Remove two mounting bolts and washers (L). Remove implement pump (M). The weight of the implement pump is 59 kg (130 lb).

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Illustration 7	g01005511
Callout (U) is for future reference.

Remove four bolts (S), hose assembly (T), and elbow (G) .

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Illustration 8	g00899750

Remove four bolts (V) and hose assembly (K) .

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Illustration 9	g00903302

Remove four bolts (W) in order to remove hose assembly (E) .

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Illustration 10	g00900148

Remove hose assembly (X), hose assembly (Z), and adapter (Y) .

Removal Procedure for Machines with the 174-8147 Vane Pump

Note: The suction hose assembly is connected to the upper side of the 174-8147 Vane Pump . This pump is normally found on D10R (S/N: 3KR1462-UP) Track-Type Tractors. If your machine does not have a 174-8147 Vane Pump see ""Removal Procedure for Machines with the 9T-1080 Vane Pump " ".

Note: To make identifying hoses easier, most graphics are shown while the vane pump is still installed.

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Illustration 11	g00904649
Typical Implement Pump

Disconnect hose assembly (C), hose assembly (D), and hose assembly (E) .

Remove the four mounting bolts that hold pressure control valve (B) to the pump. Remove pressure control valve (B) .

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Illustration 12	g00905022
Typical Implement Pump

Disconnect hose assembly (K) from elbow (H) by removing four bolts (J) .

Remove four bolts (F) from elbow (G). Tie the hoses out of the way in order to remove the implement pump.

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Illustration 13	g00607518

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Illustration 14	g00899458
Callout (Q) is for future reference.

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Illustration 15	g00904890
Typical Implement Pump

Remove hose assembly (R). Remove connector assembly (P) from hose assembly (N) .

Attach Tooling (A) to the cab ceiling and implement pump (M), as shown.

Remove two mounting bolts and washers (L). Remove implement pump (M). The weight of the implement pump is 59 kg (130 lb).

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Illustration 16	g01005560
Callout (U) is for future reference.

Remove four bolts (S), hose assembly (T), and elbow (G) .

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Illustration 17	g00899460

Remove four bolts (V) and hose assembly (K) .

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Illustration 18	g00899741

Remove four bolts (W) and hose assembly (E) .

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Illustration 19	g00899740

Remove hose assembly (AA) .

Installation Procedure for the New Gear Pump and the New Hydraulic Lines

Note: To make identifying hoses easier, most graphics are shown after the gear pump has been installed.

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Illustration 20	g00903528

If you performed the "Removal Procedure for Machines with the 9T-1080 Vane Pump ", install O-ring (1) and plug (2) into the port that was formerly occupied by the adapter (Y) in Illustration 10.

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Illustration 21	g00904806
Typical Implement Pump

Install O-ring (4) onto gear pump (3) .

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Illustration 22	g00607518

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Illustration 23	g00903478

Position gear pump (3) with a suitable lifting device. The weight of the gear pump is 69 kg (153 lb). Use Tooling (A), existing washers and existing bolts (L) to install gear pump (3) .

Remove Tooling (A) .

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Illustration 24	g00901846

Install O-ring (5) and O-ring (7) onto elbow (6) .

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Illustration 25	g00901691
For additional information, see Illustration 4 or Illustration 14.

Connect hose assembly (8) to gear pump (3) and elbow (Q). Install elbow assembly (6) to gear pump (3). Connect existing hose assembly (N) to elbow (6) .

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Illustration 26	g00986629

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Illustration 27	g00985932
For additional information, see Illustration 7 or Illustration 16.

Install seal (21) and plug (20) to elbow (9) .

Install seal (19) and elbow (9) to gear pump (3) with existing four bolts (F). Install seals (10) in each end of hose assembly (11). Use existing four bolts (S) and existing four bolts (U) to install hose assembly (11) .

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Illustration 28	g00902704
For additional information, see Illustrations 3 and 8 or see Illustrations 12 and 17.

Install hose assembly (12) with existing bolts (V), and existing bolts (J) .

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Illustration 29	g00985957

Install valve (B) to gear pump (3) with the mounting bolts.

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Illustration 30	g00902683
For additional information, see Illustration 9 or Illustration 18.

Install hose assembly (13) with existing four bolts (W) and existing four bolts (BB) .

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Illustration 31	g00902998

Connect hose assembly (14) to elbow (CC) on the hydraulic tank and elbow (DD) .

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Illustration 32	g00899775

If your machine is not equipped with bracket (15), install bracket (15) with existing bolt (EE) .

Use washer (16), clip (17), and bolt (18) to secure hose assembly (14) to bracket (15) .
Note: If your machine was already equipped with bracket (15), secure hose assembly (14) to the bracket with the existing washer, the existing clip, and the existing bolt.

Install the floorplate.

Close the drain port.

Refer to Operation and Maintenance Manual, SEBU6969, "Lubrication Viscosities and Refill Capacities" for all fluid capacities and filling procedures.

Machine Preparation for Operation

Clean up the hydraulic system thoroughly. Refer to Contamination Control Guidelines, SEBF8456, "(D7-D11) Track-Type Tractor". Additional guidelines in the product support recommendations at the following web sites: http://productsupport.cat.com/cc/cc.htm and https://nacd.cat.com/infocast/frames/prodsupp/cc/

If the hydraulic tank was not cleaned before the removal of the pump, clean the inside of the hydraulic tank. If dirt and/or metallic particles are present, clean the cylinders and other components.
Note: You can separate the halves of the tank in order to clean the tank or you can remove the filter and reach into the tank in order to clean the tank.

Install high efficiency clean up filter elements 139-1537 Oil Filter Element As (6 micron).

Run the tractor at the low idle for 10 minutes. Check the tractor for leaks. Do not operate the implements.

Increase the engine speed to high idle. Idle the engine for 15 minutes and cycle implements intermittently without stalling the cylinders at the end of stroke. Refill the hydraulic tank.

Run the tractor in working conditions for two hours.
Note: If noise occurs in the hydraulic system, the filter may be plugged. If the filter is plugged remove the high efficiency clean up filter and install new elements 139-1537 Oil Filter Element As (6 micron). Run the tractor in working conditions for another two hours.

Run the tractor in low idle for 10 minutes.

Take an oil sample. If the sample meets the ISO = 19/16 specifications, go to Step 9. If the sample does not meet the ISO = 19/16 specifications, change the high efficiency filter and repeat Step 6 through Step 8.

Install 1R-0777 Filter Elements (25 micron).

Continue the SOS for every 250 hours.

Continue the change interval for the hydraulic filter for every 500 hours.

Continue an oil change interval for every 2000 hours.

Standard Torque for Fasteners

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Table 3
Nuts and Bolts
Thread Size		Standard Torque ⁽¹⁾
Metric	Inch	Standard Torque ⁽¹⁾
M6		12 ± 3 N·m (9 ± 2 lb ft)
	1/4	12 ± 3 N·m (9 ± 2 lb ft)
	5/16	25 ± 6 N·m (18 ± 4 lb ft)
M8		28 ± 7 N·m (21 ± 5 lb ft)
	3/8	47 ± 9 N·m (35 ± 7 lb ft)
M10		55 ± 10 N·m (41 ± 7 lb ft)
	7/16	70 ± 15 N·m (50 ± 11 lb ft)
M12		100 ± 20 N·m (75 ± 15 lb ft)
	1/2	105 ± 20 N·m (75 ± 15 lb ft)
M14		160 ± 30 N·m (120 ± 22 lb ft)
	9/16	160 ± 30 N·m (120 ± 22 lb ft)
	5/8	215 ± 40 N·m (160 ± 30 lb ft)
M16		240 ± 40 N·m (175 ± 30 lb ft)
	3/4	370 ± 50 N·m (275 ± 37 lb ft)
M20		460 ± 60 N·m (340 ± 44 lb ft)
	7/8	620 ± 80 N·m (460 ± 60 lb ft)
M24		800 ± 100 N·m (590 ± 75 lb ft)
	1	900 ± 100 N·m (660 ± 75 lb ft)
	1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
M30		1600 ± 200 N·m (1180 ± 150 lb ft)
	1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
	1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
M36		2700 ± 300 N·m (2000 ± 220 lb ft)
	1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

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^( 1 )

Refer to Specifications, SENR3130, "Torque Specifications" or the topic "Torque Specifications" in the Operation and Maintenance Manual of your machine for additional information.