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Hydraulic Piston Pumps Used in 416, 426, 428, 436, 438, 446, 446B Backhoe Loaders; 12G, 14G, 14H, 16G, 16H, 120G, 130G, 140G, 140H, 160G, 160H Motor Graders; and D4H, D5H, D6H, D8L Track-type Tractors
SMCS - 3203; 5070; 5084
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16H, 120G, 130G, 140G, 140H, 160G, 160H Motor Graders; and D4H, D5H, D6H, D8L Track-type Tractors
Summary of Revisions
Page
Description
All
Revised Format.
Introduction
This Guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to its products, this Guideline must be used with the latest technical information available from Caterpillar to ensure such changes and improvements are incorporated where applicable. For questions or additional information concerning this Guideline, contact Caterpillar Service Support Division, Dealer Support (309) 675-5156.
Summary
The purpose of this Guideline is to give visual guidelines to see if piston pump and motor parts can be used again. When used in the same application, parts that can be used again can be expected to give normal performance until the next overhaul. Never install a part that this Guideline shows cannot be used again. During reconditioning, correct any conditions that might have caused the original failure.
References
Reference Material
Form
Title
SEBF2000
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Part No.
Description
Optical Flat
Inside Micrometer
V-Block
7B0337
Surface Plate
4C5043
4C5852
Pins
4C5853
Pins
4C5854
Pins
4C5855
Pins
4C5856
Pins
8T5096
6V7898
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6V7899
Cleaning Procedure
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure must be below 200 kPa (30 psi) for cleaning purposes. Use all cleaning solutions and solvents with care.
Before a part is inspected, wash it in a clean solvent which is made from petroleum. Wash each part separately. If several parts are washed together, there is a possibility that a machined surface can be damaged. Use compressed air to dry the part. Put hydraulic oil on the part to prevent rust or corrosion. Put the part in a clean container. Use a lint-free towel to clean the part before assembly. Be sure to put oil on all of the parts during assembly.
Inspection Procedure
Piston pump and motor parts normally have wear patterns that can be seen but can not be felt with a fingernail or lead pencil after the salvage procedure. This type of wear has no effect on the performance of the part. Unless stated in this Guideline, parts that have wear patterns that can be felt with a fingernail or lead pencil after the salvage procedure can not be used again. Throughout this Guideline, the fingernail or lead pencil inspection will be used to see if a part can be used again.
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paper. Move the part in a pattern like a number "8". Normally it is not necessary to make more than 10 complete number "8" patterns. Wash the part in a clean solvent. Let the part dry at room temperature. Put hydraulic oil on the part and then put the part in a clean container.
NOTICE When you handle or put pump and motor parts in storage, care must be taken to prevent damage to the machined surfaces.
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Load the parts to be lapped inside the conditioning rings. The parts should be free to move about within the ring, and not packed such that they remain stationary. Lapping times will vary according to the severity of the flaw that is to be removed. Minor scratches or warpage can usually be removed within 30 to 60 minutes. In order to inspect the flatness of the lapped part, remove the dull finish that is caused by the lapping compound. Wash the part thoroughly. Polish the lapped surface, using 600 grit emery paper on a 4/0 polishing stand, until it will reflect light.
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Illustration 5 Nomenclature. (1) Barrel Assembly, (2) Piston Assembly, (3) Retraction Plate, (4) Wear Plate, (5) Spacer.
Piston Assembly
Piston Slipper
Check to see if the slipper will move by hand on the piston ball. The slipper can feel loose or tight but must move in all directions without binding. If binding is felt, do not use the piston assembly again. Note: Be sure the lubrication port is not plugged. Use a wire to check the hole.
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Use again
Illustration 7 Slipper face nomenclature. (6) Bearing Area, (7) Lubrication Port, (8) Piston, (9) Balance Land.
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Illustration 8 Slipper face nomenclature. (6) Bearing Area, (7) Lubrication Port, (8) Piston, (9) Balance Land.
Note: Polishing marks on the new faces are normal. These marks can not be felt with a fingernail or lead pencil.
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Illustration 10 Piston slipper with light scratches that can be felt with a fingernail or lead pencil.
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Illustration 12 Piston slipper with large "pop outs" and metal embedded in bearing area.
Piston Assembly
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Use again
Illustration 15 Piston assembly with scratches that can be felt with a fingernail or lead pencil.
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Illustration 16 Piston assembly with metal flakes or scratches that can be felt with a fingernail or lead pencil.
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Illustration 18 Piston on left has light surface scratches that can not be felt with a fingernail or lead pencil.
Use again
Piston on right has light surface scratches that can be felt with a fingernail or lead pencil.
Illustration 19
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Illustration 21 Piston exposed to severe contamination that has seized in piston bore.
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Specifications
Piston Slipper Thickness
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Measure the thickness of the slipper face with a 0 to 25 mm (0 to 1.0 in) micrometer. If the dimension measured is less than the piston slipper thickness given in Chart A, the piston assembly can not be used again.
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The slipper faces of all the pistons from a single pump or motor must be measured. There must not be a difference of more than 0.02 mm (.001 in) between the thickest and thinnest dimension in a set of pistons. If a new piston assembly is used in a set with used piston assemblies and the new piston slipper is more than 0.02 mm (.001 in) thicker than the other pistons in the set, the touch lapping procedure can be used to make the new slipper thinner.
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the end of the piston. Push down on the piston and set the dial indicator at zero. Pull up on the piston. End play movement cannot exceed 0.13 mm (.005 in).
Illustration 28 Slipper end play limits. (H) Pull up. (J) Push down. (K) Endplay of 0.13 mm (.005 in).
Barrel Assembly
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Illustration 29 Nomenclature, (10) Seal Bands, (11) Port, (12) Splines, (13) Thrust Surface.
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Illustration 32 Barrel assembly with polished surface and no wear step in the seal band and thrust surface.
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Use again
Illustration 33 Barrel assembly with discoloration. Scratches in the block surface can not be felt with a fingernail or lead pencil. Use again
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1. Wash the barrel assembly and piston in a clean solvent. Use compressed air to dry off the barrel assembly and piston.
Illustration 35 How to check the side movement of a piston in a barrel assembly bore.
1. 2. Put a piston into one of the bores to the maximum depth that the piston will go into the bore during operation. 3. Feel for side movement of the piston in the bore. Do this for all of the bores. If no movement or only very little side movement can be felt in all of the bores, the barrel assembly can be used again. NOTE: Use a piston in a new barrel assembly to see how much side movement can be permitted. If necessary, use a dial bore gauge to measure the bore diameters. If any of the bore measurements are more than the maximum measurement given in Chart B, the barrel assembly can not be used again.
Chart B. Barrel Bores
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Illustration 36 Measurement of barrel bores; and measurement of barrel length and barrel face. See Charts B and C.
The barrel length must not be less than the dimension given in Chart C.
The barrel face, identified in Illustration 36, must be perpendicular to the splines within 0.05 mm (.0015 in).
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The barrel face can not exceed a surface finish of 0.20 m (8 in). The barrel face must be flat within 0.0013 mm (.00005 in).
Use two 4C5856 Pins, 2.74 mm (.108 in), for the spline measurement.
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Retraction Plate
Check the retraction plate to make sure it is flat. Put the plate on a surface plate (7B0337 Plate). With fingers and thumb, push down on opposite edges and see if any rocking motion can be felt. If rocking motion can be felt, the plate is not flat and can not be used again unless made flat by grinding.
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Illustration 41 This plate shows damage from slipper "lifting". Also, polished or scored surfaces on the area where the spherical washer rides is not acceptable.
Wear Plate
Illustration 42 Wear plate with a scratch across the slipper seat area that can be felt with a fingernail or lead pencil. Wear plates should not be used again without first power lapping to remove scratches.
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Use again
Use again
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Illustration 44 Wear plate with scratches that can not be felt with a fingernail or lead pencil.
Use again
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Use again
Use again
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Illustration 47 Wear plate with groove and wear step in the slipper seal area.
Illustration 48 Wear plate with heat cracks that can be felt with a fingernail or lead pencil.
Illustration 49
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Port Plate
Illustration 51 Nomenclature. (14) Rib, (10) Seal Band, (15) Thrust Face, (11) Port.
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Note: Use the power lapping procedure on both sides of all port plates that can be used again before they are installed. The port plate thickness must not be less than the dimension given in Chart E.
Chart E. Port Plate Thickness
Minimum Thickness
The port plate face, as shown in Illustration 52, must have a surface finish of 0.20 m (8 in).
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The port plate face must be flat within 0.0013 mm (.00005 in).
Illustration 54 Port plate with erosion not more than half way into the seal band.
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Use again
Illustration 56 Port plate with scratches in the seal band and thrust surface that can not be felt with a fingernail or lead pencil.
Use again
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Illustration 57 Port plate with scratches across the seal band that can be felt with a fingernail or lead pencil.
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Head Assembly
Note:
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The surface shown in Illustrations 60, 61, and 62 can be power lapped a maximum of 0.38 mm (.015 in). Metering notches must be altered accordingly. Bearing must be removed and replaced.
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Swashplate
Illustration 64 Swashplate with discoloration and polishing on the wear plate surface.
Use again
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Illustration 65 Swashplate with buttons that are polished but with no deep grooves or scoring.
Use again
Illustration 66 Swashplate bolts are subject to continuous loading/unloading frequencies. Incorrect tightening of the bolt can cause splitting breakage as shown.
Shafts
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Illustration 67 Nomenclature. (16) Seal surface, (17) Output splines, (18) Crown splines.
Illustration 68 Shaft with wear in the seal surfaces that can be seen but can not be felt with a fingernail or lead pencil.
Use again
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Use again
Illustration 70 Shaft with wear on the splines. No wear steps can be seen.
Use again
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Illustration 71 Shaft with wear on the splines. Wear steps can be seen.
Spline Measurement
If the splines have a visible wear step, the shaft can not be used again. If necessary, measure the splines. Use two pins in splines 180 apart. For those shafts that have an odd number of spline teeth, put the pins in splines as near to
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180 apart as possible. Put rubber bands around the pins and shaft to keep the pins in place. Use an outside diameter micrometer to measure across the pins.
Illustration 73 Measurement of both pump shaft splines over pins. See Charts F and G.
The crown splines of the pump shaft must not be less than the dimension given in Chart F. Use two 4C5855 Pins, 3.05 mm (.120 in), for the spline measurement. These pins are not an actual pump part but a tooling device and can be ordered through Caterpillar Parts system. Crown spline measurements must be taken from the center of the splines to assure accuracy (See Illustration 73). Feel for a wear step with a lead pencil or finger nail. If a wear step is evident, be sure to position pins in the worn area.
Chart F. Crown Splines of Pump Shaft
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The output splines of the pump shaft must not be less than the dimension given in Chart G.
Pin Diameter
9T2016
4C5855
9T3039
4C5855
9T3932
4C5852
9T6755
4C5853
9T9461
4C5854
9T3933
4C5855
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9T1634
4C5855
9T7783
4C5854
9T8629
4C5855
9T9457
4C5855
9T8648
4C5854
Use again after the seal area is salvaged according to the correct procedure (see Procedure to Salvage Shaft Seal Area).
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Illustration 76 Inspection of pins and spherical washer in the rotating group. (19) Pins, (20) Spherical Washer, (21) Plate, (22) Retainer, (1) Barrel Assembly.
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Pins (19) shown in Illustration 76 must be straight and of equal length on the 9T6857, 9T0290, 4T1029 and 4T6895 Hydraulic Pumps. Replace all pins if one is defective. For those pumps with a 17.04 mm (.671 in) reference piston diameter, inspect spherical washer (20) shown in Illustration 76 for burrs, wear and damage due to pin breakage.
Summary Charts
The following charts summarize all of the specifications listed in this Guideline and provide a single specification sheet for new dimensions for piston pump components.
(A)
(B)
(C)
(D)
(E)
(E)
17.04 (.671)
3.30 (.130)
17.07 (.672)
72.62 (2.859)
24.71 (.973)
97.92 (3.855)
5.00 (.197)
19.23 (.757)
5.29 (.208)
19.29 (.759)
92.25 (3.632)
32.59 (1.283)
101.35 (3.990)
6.02 (.237)
20.90 (.823)
5.57 (.219)
20.96 (.825)
98.65 (3.884)
35.79 (1.409)
112.50 (4.429)
6.40 (.252)
23.04 (.907)
5.05 (.199)
23.09 (.909)
113.75 (4.478)
38.96 (1.534)
121.62 (4.788)
8.43 (.332)
26.11 (1.028)
5.97 (.235)
26.17 (1.030)
119.64 (4.710)
45.34 (1.785)
138.66 (5.459)
8.61 (.339)
Use two 4C5856 Pins, 2.74 mm (.108 in), to find the minimum dimension between pins for spline measurement.
Pin Diameter
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17.04 (.671)
33.0 (1.302)
9T2016
3.05 (.120)
4C5855
28.24 (1.112)
17.04 (.671)
33.12 (1.304)
9T3933
3.05 (.120)
4C5855
28.24 (1.112)
17.04 (.671)
33.12 (1.304)
9T3932
2.03 (.080)
4C5852
23.06 (.908)
19.23 (.757)
40.97 (1.613)
9T3039
3.05 (.120)
4C5855
28.24 (1.112)
19.23 (.757)
40.97 (1.613)
9T6755
4.57 (.180)
4C5853
35.69 (1.405)
20.90 (.823)
44.15 (1.738)
9 634
3.05 (.120)
4C5855
31.34 (1.234)
20.90 (.823)
44.15 (1.738)
9T9457
3.05 (.120)
4C5855
18.44 (.726)
23.04 (.907)
47.35 (1.864)
9T9461
4.06 (.160)
4C5854
35.69 (1.405)
23.04 (.907)
47.35 (1.864)
9T7783
4.06 (.160)
4C5854
35.69 (1.405)
23.04 (.907)
47.35 (1.864)
9T8648
4.06 (.160)
4C5854
35.69 (1.405)
26.11 (1.028)
53.70 (2.114)
9T8629
3.05 (.120)
4C5855
18.44 (.726)
Use two 4C5855 Pins, 3.05 mm (.120 in), to find the minimum dimension over pins for spline measurement.
Copyright 1993 - 2012 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
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