June 2002
Systems Operation
Disassembly and
Assembly
Generic Vane Pump
9KW1-Up (Machine)
i01658146
3
Vane Pump
Table of Contents
Table of Contents
Systems Operation Section
General Information
General Information ................................................ 4
Component Descriptions ........................................ 5
Identity Information ................................................. 7
Troubleshooting
Troubleshooting ..................................................... 8
11
14
18
20
Index Section
Index ..................................................................... 25
4
Vane Pump
Systems Operation Section
General Information
SMCS Code: 5055
1. The V model pumps are designed to provide
hydraulic fluid flow for the operation of industrial
equipment. The VQ model pumps are designed
to provide hydraulic fluid flow for the operation of
mobile equipment.
2. Pump cartridges provide the positive
displacement of hydraulic fluid. The size and the
drive speed of the pump determines the flow
rate.
3. Changes in direction of rotation, port positions,
and pumping capacity are easily made.
Illustration 1
Balanced cartridge
g00886749
5
Vane Pump
Systems Operation Section
g00886750
Illustration 2
i01714319
Component Descriptions
SMCS Code: 5055
Illustration 3
g00886409
6
Vane Pump
Systems Operation Section
Illustration 4
g00888313
Illustration 6
g00886409
Illustration 7
g00888313
Illustration 5
g00886457
7
Vane Pump
Systems Operation Section
Table 2
Torque Values
Series
Cover
Bolt
Housing
Bolt
Cover
Cartridge
Kit Screw
Shaft
Cartridge
Kit Screw
2520
61 6.8
Nm (45
5 lb ft)
95 6.8
Nm (70
5 lb ft)
41 6.8
Nm (30
5 lb ft)
61 6.8
Nm (45
5 lb ft)
3520
61 6.8
Nm (45
5 lb ft)
203
13.5 Nm
(150
10 lb ft)
41 6.8
Nm (30
5 lb ft)
142 6.8
Nm (105
5 lb ft)
3525
95 6.8
Nm (70
5 lb ft)
203
13.5 Nm
(150
10 lb ft)
61 6.8
Nm (45
5 lb ft)
142 6.8
Nm (105
5 lb ft)
4520
61 6.8
Nm (45
5 lb ft)
359
13.5 Nm
(265
10 lb ft)
41 6.8
Nm (30
5 lb ft)
142 6.8
Nm (105
5 lb ft)
4525
95 6.8
Nm (70
5 lb ft)
359
13.5 Nm
(265
10 lb ft)
61 6.8
Nm (45
5 lb ft)
142 6.8
Nm (105
5 lb ft)
4535
359
13.5
Nm
(265
10 lb ft)
****
142 6.8
Nm (105
5 lb ft)
142 6.8
Nm (105
5 lb ft)
g00886410
Illustration 8
Identity Information
SMCS Code: 5055
Table 1
Torque Values
Series
Cover Bolt
25
203 13.5 Nm
(150 10 lb ft)
142 6.8 Nm
(105 5 lb ft)
35
203 13.5 Nm
(150 10 lb ft)
142 6.8 Nm
(105 5 lb ft)
359 13.5 Nm
(265 10 lb ft)
142 6.8 Nm
(105 5 lb ft)
45
g00888241
8
Vane Pump
Systems Operation Section
9. Mounting (9).
Illustration 10
g00888242
Troubleshooting
i01714534
Troubleshooting
SMCS Code: 5055
Note: The following table contains a list of common
problems. The problems are followed by probable
causes and possible solutions.
Note: In many cases, apparent pump failures
are actually failures in other parts of the system.
Thorough knowledge and proper test equipment is
the most reliable diagnostic procedure.
9
Vane Pump
Systems Operation Section
Table 3
Problem
Probable Cause
The pump
does not
deliver fluid.
Inspect the hydraulic lines for ruptures. Replace the lines, as needed.
Inspect all inlet connections for air leakage. Tighten any loose connections.
Inspect filters and strainers for dirt or sludge. Clean the filters or replace
the filters, as needed.
Drain fluid from the system. Refill with new, filtered fluid of the proper
viscosity.
Check fluid level in the reservoir. Ensure that the inlet opening is covered.
Add new filtered fluid, as needed. Ensure that the pump is operating above
the required minimum drive speed.
In order to change the rotation of the pump, the pump must be shut down.
Disassemble the pump and the cartridge. Inspect all parts for metal chips or
dirt. Ensure that the vanes move freely within the slots in the rotor. Clean all
parts and replace damaged parts.
Inspect the system for possible fluid leakage. Replace any damaged parts.
Disassemble the pump and the cartridge. Reassemble the cartridge for the
proper direction of rotation.
Inspect the inlet lines for damage. Inspect the inlet lines for improper
connections. Inspect the outlet lines for damage. Inspect the outlet lines for
improper connections. Reconnect the lines to proper ports. Replace the
lines, as needed.
The
system has
insufficient
pressure.
Possible Solution
Inspect the drive mechanism for damage. Ensure that the drive is properly
connected to the pump shaft. Replace the damaged parts, as needed.
(continued)
10
Vane Pump
Systems Operation Section
(Table 3, contd)
Excessively
noisy pump
operation
Refill the reservoir to the proper level with new, filtered fluid.
Drain fluid from the system. Refill with new, filtered fluid of the proper
viscosity.
Inspect filters and strainers for dirt or sludge. Clean the filters or replace
the filters, as needed.
Inspect inlet connections for air leakage. Tighten any loose connections.
Inspect seals for damage. Replace the seals,as needed.
Check the fluid level in the reservoir. Ensure that the inlet opening is covered.
Add new filtered fluid, as needed.
Remove the reservoir cap and operate the pump until air is purged from
the system.
While the system is under pressure, bleed air from the hydraulic lines
downstream from the pump.
Overheated
pump
Inspect the inlet line for damage. Inspect the inlet lines for the proper
connection. Inspect the outlet line for damage. Inspect the outlet line for
the proper connection. Reconnect the lines to the proper port. Replace the
lines, as needed.
Ensure that the pump is operating above the minimum drive speed.
Inspect the shaft seals and bearing for damage. Replace parts, as needed.
Inspect the heat exchanger for damage. Repair the heat exchanger, as
needed.
11
Vane Pump
Disassembly and Assembly Section
i01716152
Required Tools
Tool
Part Number
Part Description
Qty
1P-1859
1P-0510
Driver Gp
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.
Illustration 11
g00878060
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, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.
Illustration 12
g00878093
12
Vane Pump
Disassembly and Assembly Section
Illustration 13
g00878097
Illustration 15
g00878104
Illustration 16
Illustration 14
g00878100
g00885309
13
Vane Pump
Disassembly and Assembly Section
Illustration 17
g00885310
Illustration 18
g00885311
Illustration 19
g00885312
Illustration 20
g00885313
Illustration 21
g00885314
Illustration 22
g00885315
14
Vane Pump
Disassembly and Assembly Section
Note: Pictures are typical examples.
g00885316
Illustration 23
Illustration 25
g00878610
Illustration 26
g00878611
g00885317
Illustration 24
Required Tools
Tool
Part
Number
Part Description
Qty
15
Vane Pump
Disassembly and Assembly Section
Illustration 27
g00878615
Illustration 29
g00878097
Illustration 30
g00878093
Illustration 28
g00878622
16
Vane Pump
Disassembly and Assembly Section
Illustration 33
g00885316
Illustration 31
g00878060
Illustration 32
Illustration 34
g00885317
g00885315
Illustration 35
g00885324
17
Vane Pump
Disassembly and Assembly Section
Illustration 36
g00885313
Illustration 37
g00885312
Illustration 38
g00885311
Illustration 39
g00885310
Illustration 40
g00885309
10. Install cover (2) to body (3). Install four bolts (1)
to cover (2).
18
Vane Pump
Disassembly and Assembly Section
i01716649
Disassembly Procedure
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.
Illustration 41
g00885330
Illustration 42
g00877566
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, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Note: All pumps are designed so changes in
direction of rotation, port positions, and pumping
capacity are easily made.
Note: This section is only for changing the rotation
of the pump. Parts at this level are nonserviceable.
Note: Cleanliness is an important factor. Before
the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
mechanism.
1. Pump rotation is viewed from the shaft end.
Cartridges are normally assembled for right hand
rotation.
19
Vane Pump
Disassembly and Assembly Section
Illustration 43
g00885331
Illustration 44
g00885332
Illustration 45
g00885333
Illustration 46
g00885334
20
Vane Pump
Disassembly and Assembly Section
Illustration 47
g00885335
Assembly Procedure
Note: This section is only for changing the rotation
of the pump. Parts at this level are nonserviceable.
21
Vane Pump
Disassembly and Assembly Section
Illustration 48
g00883128
22
Vane Pump
Disassembly and Assembly Section
Illustration 49
g00883127
23
Vane Pump
Disassembly and Assembly Section
1. Pump rotation is viewed from the shaft end.
Cartridges are normally assembled for right hand
rotation.
2. Reverse the rotation of a new cartridge. Rotate
the following parts180 degrees.
Flex Plates
Cam Ring
Rotor
Vanes
3. Reverse the rotation of a new cartridge. Turn the
following parts 180 degrees: flex plates, cam
ring, rotor, and vanes.
Illustration 50
Illustration 52
g00885334
Illustration 53
g00888319
g00877566
Illustration 51
g00885335
24
Vane Pump
Disassembly and Assembly Section
Illustration 54
g00885333
Illustration 56
g00885331
Illustration 55
g00885332
25
Vane Pump
Index Section
Index
C
Cartridge Assembly - Assemble ............................ 20
Assembly Procedure.......................................... 20
Cartridge Assembly - Disassemble ....................... 18
Disassembly Procedure ..................................... 18
Component Descriptions ......................................... 5
D
Disassembly and Assembly Section...................... 11
G
General Information................................................. 4
H
Hydraulic Pump - Assemble ..................................
Double Vane Pump Assembly Procedure ..........
Single Vane Pump Assembly Procedure ...........
Hydraulic Pump - Disassemble .............................
Double Vane Pump Disassembly Procedure .....
Single Vane Pump Disassembly Procedure ......
14
16
14
11
12
11
I
Identity Information .................................................. 7
Important Safety Information ................................... 2
S
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Troubleshooting ....................................................... 8
26
Vane Pump
Index Section
27
Vane Pump
Index Section
2002 Caterpillar
All Rights Reserved
Printed in U.S.A.