12/29/22, 10:04 AM SIS 2.

2022/07/06 Hydraulic Pump - Remove and Install (M0069644-49)

SMCS - 5073 i09430614

Removal Procedure

PIP
Required Tools
Tool Part Number Part Description Qty
A
B
-
-
Loctite 243
Silicone Sealant
-
-
202 025
-
1
Table 1

2
13: /12/2 417 4
0
M0 :18- 4 9
Hot hydraulic oil under high pressure can remain in the
components of the hydraulic system or the power train system

0 0
after the engine has been stopped. The uncontrolled release of

6
© 2 964 3:00
the hydraulic oil can cause sudden machine movement and can
also result in the following conditions:

Burns

0
Cat 2 C2 4
The penetration of body tissue

Other personal injury

e r
Con pilla terpia
Death

If hydraulic oil penetrates body tissue, the injury must be treated

fide r: llar
immediately by a doctor who is familiar with this type of injury.
Use a board or a piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have been lowered to

ntia Inc
the ground and that all trapped pressure has been released from
the hydraulic system and the power train system. Also, make

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sure that the hydraulic oil is cool before the removal of any
components or lines. Remove the hydraulic oil filler cap only
when the engine is stopped and the filler cap is cool enough to

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touch with your bare hand.

n
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.

Note: Before the roof panels are removed, barricade the hole or set up flagging to warn personnel so that workers do not fall through the open hole
and get injured. Use appropriate fall protection.

Note: Hydraulic hoses must be depressurized before disconnecting from the pumps. The hydraulic fluid is under high pressure and could spray out
with enough force to penetrate exposed skin.

Note: Ensure that you have constant radio contact with the crane operator when equipment parts are moved with the mobile crane. Many of these
lifts are “blind” and radio communication helps to prevent accidents such as dropped loads, which could cause serious injury or equipment
damage.

Note: Put identification marks on the hose assemblies, the tube assemblies, and the wire harnesses for installation purposes. Plug all the hose
assemblies and the tube assemblies to prevent fluid loss and prevent contaminants from entering the system.

1. Prepare the machine for maintenance, perform voltage shutdown.

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a. For (S/N: ER6 and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.

b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.

Illustration 1 g06159110
2. Attach suitable lifting device to handrail (1). The weight of handrail (1) is approximately 43 kg (95 lb).

3. Remove bolts (2) and handrail (1).

Illustration 2 g06159112

4. Attach suitable lifting device to handrail (3). The weight of handrail (3) is approximately 45 kg (99 lb).

5. Remove bolts (4) and handrail (3).

Illustration 3 g06159113

6. Attach a suitable lifting device to roof platform (6). The weight of roof platform (6) is approximately 127 kg (280 lb). The weight of roof platform
(8) is approximately 136 kg (300 lb).

7. Remove bolts (5) and the plates.

8. Remove u-bolts (7) and remove roof platforms (6).

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Illustration 4 g06159114
9. Attach a suitable lifting device to roof platform (8). The weight of roof platform (8) is approximately 136 kg (300 lb).

10. Remove bolts (9) and the plates.

11. Remove u-bolts (10) and remove roof platforms (8).

Illustration 5 g06159115

12. Attach suitable lifting device to roof support beam (11). The weight of roof support beam (11) is approximately 364 kg (802 lb).

13. Remove bolts (12) and roof support beam (11).

Illustration 6 g06159116

14. Remove bolts (13) and the roof clips that hold roof panel (15).

15. Attach a suitable lifting device to d-rings (14) of roof panel (15). The weight of roof panel (15) is approximately 395 kg (871 lb). Remove roof
panel (15).

Illustration 7 g06159119

16. Disconnect hose assembly (16). Repeat for the other side.

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Illustration 8 g06159120
17. Remove lock pins (18) and panels (17).

Illustration 9 g06159124

18. Move isolation valve (19) to CLOSED position.

Illustration 10 g06159125

19. Disconnect hose assemblies (20) from the pump. Drain the hydraulic oil into a suitable container for storage or proper disposal.

Illustration 11 g06159176

20. Disconnect hose assembly (21) and remove the O-ring seal from the pump. Drain the hydraulic oil into a suitable container for storage or
proper disposal.

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Illustration 12 g06159128
21. Disconnect hose assembly (22) and remove the O-ring seal from the pump. Drain the hydraulic oil into a suitable container for storage or
proper disposal.

Illustration 13 g06159130

22. Attach suitable lifting device to pump (24). The weight of pump (24) is approximately 159 kg (351 lb).

23. Remove bolts (23) and the washers. Remove pump (24) and the O-ring seal.

Installation Procedure
1. Verify that the machine is prepared for maintenance.

a. For (S/N: ER6 and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.

b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.

2. Install pump (26) in the reverse order of removal.

Note: When installing the pumps, rotate the shaft of the pump drive transmission, not the pump shaft. If excessive shaft rotation occurs,
remove the pump and verify the position of the timing mark. Incorrect positioning could result in equipment failure.

Illustration 14 g06159393

a. Use large channel-lock pliers with a rag to protect the pump shaft teeth. Rotate the pump shaft until timing mark (C) is centered in the
upper case drain port.

b. Use a paint stick or marker to mark the tooth on the pump shaft that lines up with the timing mark.

c. Replace the top case drain plug in the top case drain port.
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3. If, more than one pump is replaced follow the Steps below.

a. For each pump, mark the tooth on the pump shaft that lines up with the timing mark.

Illustration 15 g06159394
(D) Timing mark on pump housings

Illustration 16 g06159395
(E) Punch mark output gear groove to match mating "TDC" pump spline tooth

b. Position the first pump P1 in the TDC position.

c. To position the second pump P2, face the pump shaft and count 15 teeth in a counter-clockwise direction from the TDC position. Mark
the pump housing.

d. To position the third pump P3, face the pump shaft and count seven teeth in a counter-clockwise direction from the TDC position. Mark
the pump housing.

e. To position the fourth pump P4, face the pump shaft and count 11 teeth in a counter-clockwise direction from the TDC position. Mark the
pump housing.

f. Using large channel-lock pliers with a rag to protect the pump shaft teeth. Rotate the pump shaft of P2, P3, and P4 counter-clockwise to
align the marked tooth with the mark on the pump housing.

g. Verify the tooth count on each pump.

h. Punch mark the spline groove of the output gear to coincide with the mating TDC marked pump spline tooth.

i. Replace the top case drain plug in the top case drain port on each pump.

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Illustration 17 g06159396
j. Tighten bolts (23) to a torque of 379 N·m (280 lb ft). Tighten bolts (23) in a pattern as shown in Illustration 17.

Illustration 18 g06159397

k. Connect the hose assemblies from pump (24) to flow meter (25) as shown in illustration 18.

l. Tighten bolts (13) to a torque of 271 N·m (200 lb ft).

m. Tighten bolts (12) to a torque of 1139 N·m (840 lb ft).

n. Tighten bolts (10), (9), (7), and (5) to a torque of 149 N·m (110 lb ft).

o. Apply Tooling (A) to the threads of bolts (4) and (2). Tighten bolts (4) and (2) to a torque of 149 N·m (110 lb ft).

PIP-10254417
2022/12/29
13:04:07-03:00
i06866019
© 2022 Caterpillar Inc.
Caterpillar:
Confidential Green

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