6/11/23, 16:25 SIS 2.

Main Hydraulic Pump - Assemble - Series II (RENR5438-15)

SMCS - 5070 i09656898

Assembly Procedure
PSP
202 -0004
Table 1

22: 3/11/0 D4CD

Required Tools
Tool Part Number Part Description Qty
A 1P-2420
2 5
Transmission Repair Stand

RE : 6 1
B 589-7434 Link Bracket As
N 0 9-0 2

© 2 R54 6:00
C 589-7433 Link Bracket As 2

023 38
D 1U-8758 Retaining Ring Pliers 1
E 141-4803 Gauge Block Set 1
F 8T-5096 Cat
Dial Indicator Test Group 1
149-4935 Measuring Tool Group erp 1
G
187-6278 Gauge Plate illa 2
H 1P-1859 Retaining Ring Pliers r In 1

J
1U-5823 Driver c. 1
5P-4197 Spacer 1
K - Loctite 243 -

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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Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the
assembly procedure.

Note: Apply a light film of "10W" oil to all components before assembly.

1. Assemble the pump control. Refer to Disassembly and Assembly, "Pump Control - Assemble"
in this manual.

Assembly Procedure for the Upper Pump Rotating Group

Illustration 1 g00681108
Cross section view of the upper pump rotating group.
(A) Dimension that is determined by shim (41)
( 37) Snap ring
(38) Bearing assembly
(39) Bearing assembly
(40) Plate
(41) Shim

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Illustration 2 g00681724
Cross section view of bearing assembly (39).
(39a) Bearing cone
(39b) Spacer
(39c) Bearing cup
(39d) Bearing spacer
(39e) Bearing cone
(39f) Bearing cup

1. Perform the stackup of bearing assembly (39) for the lower pump rotating group, as follows.

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Illustration 3 g00632629
2. Position gauge blocks from Tooling (E) on a surface plate to obtain dimension (A) of 86.5 mm
(3.41 inch).

3. Position Tooling (F) over the gauge blocks, and zero the indicator.

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Illustration 4 g00632637
Measurement that determines the thickness of shim (41)
( 41) Shim
(39) Bearing Assembly
4. Slide the bearing assembly under Tooling (F).

5. The indicator should indicate between 0.00 mm (0.000 inch) and −0.10 mm (−0.004 inch) for
the correct dimension (A).
Table 2

Table for Shim (41) (1)

Shim Thickness (mm)

177-2513 6.2
177-2514 6.3
177-2515 6.4
177-2516 6.5
177-2517 6.6
(1) Use the necessary shim (41) for adjusting dimension (A) for the upper pump rotating group.

6. Add shims (41) to obtain the correct dimension (A).

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Note: Use only one shim to obtain the stackup of bearing (39). The stackup of bearing
assembly (39) determines the position of the rotating group inside the main pump housing.
7. The following Steps 8 through 15 are for the buildup of bearing assembly (39).

Illustration 5 g00640449

8. Heat bearing cone (39a) to the maximum temperature of 100 °C (212 °F).

9. Install bearing cone (39a) onto the shaft.

Illustration 6 g00641138

10. Install spacer (39b).

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Illustration 7 g00640454
11. Install bearing cup (39c).

Illustration 8 g00640654

12. Install bearing spacer (39d).

Illustration 9 g00640658

13. Heat bearing cone (39e) to the maximum temperature 100 °C (212 °F).

14. Install bearing cone (39e) on the shaft.

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Illustration 10 g00640665
15. Install bearing cup (39f) onto the shaft. This is the final component for bearing assembly (39).

Illustration 11 g00640668

16. Install shim (41) onto the shaft.

17. Steps 18 and 19 are the components that make up bearing assembly (38).

Illustration 12 g00640671

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18. Install bearing cup (38a).

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Illustration 13
023 8 g00640676

Cat
19. Heat bearing cone (38b) to the maximum temperature of 100 °C (212 °F).

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20. Install bearing cone (38b).

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c.

Illustration 14 g00641131

21. Install plate (40).

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Illustration 15 g00641129
22. Use Tooling (G) to install retaining ring (37).

Assembly Procedure for the Lower Pump Rotating Group

Illustration 16 g00681036
Cross section view of the lower pump rotating group.
(A) Dimension that is determined by shim (36)
( 32) Snap ring
(33) Bearing assembly
(34) Bearing assembly
(35) Plate
(36) Shim

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Illustration 17 g00682774
Cross section view of bearing assembly (34).
(34a) Bearing cone
(34b) Spacer
(34c) Bearing cup
(34d) Bearing spacer
(34e) Bearing cone
(34f) Bearing cup

1. Perform the stackup of bearing assembly (34) for the lower pump rotating group, as follows.

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Illustration 18 g00632629
2. Position gauge blocks from Tooling (E) on a surface plate to obtain dimension (A) of 86.5 mm
(3.41 inch).

3. Position Tooling (F) over the gauge blocks, and zero the indicator.

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Illustration 19 g00685169
Measurement that determines the thickness of shim (36)
( 36) Shim
(34) Bearing Assembly
4. Slide the bearing assembly under Tooling (F).

5. The indicator should indicate between 0.00 mm (0.000 inch) and −0.10 mm (−0.004 inch) for
the correct dimension (A).
Table 3

Table for Shim (36) (1)

Shim Thickness (mm)

177-2487 3.3
177-2488 3.4
177-2489 3.5
(1) Use the necessary shim (36) for adjusting dimension (A) for the lower pump rotating group.

6. Add shims (36) to obtain the correct dimension (A).

Note: Use only one shim to obtain the stackup of bearing assembly (34). The stackup of
bearing assembly (34) determines the position of the rotating group inside the main pump
housing.

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7. The following Steps 8 through 15 are for the buildup of bearing assembly (34).

Illustration 20 g00640332

8. Heat bearing cone (34a) to the maximum temperature of 100 °C (212 °F).

9. Install bearing cone (34a).

Illustration 21 g00682051

10. Install bearing spacer (34b).

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Illustration 22 g00640334
11. Install bearing cup (34c).

Illustration 23 g00640335

12. Install bearing cup (34d).

Illustration 24 g00640336

13. Heat bearing cone (34e) to 100 °C (212 °F).

14. Install bearing cone (34e).

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Illustration 25 g00640397
15. Install bearing cup (34f). This is the final component for bearing assembly (34).

Illustration 26 g00640402

16. Install shim (36).

17. Steps 18 and 19 are the components that make up bearing assembly (33).

Illustration 27 g00640405

18. Install bearing cup (33a).

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Illustration 28 g00640407
19. Heat bearing cone (33b) to the maximum temperature of 100 °C (212 °F).

20. Install bearing cone (33b).

Setting the Bearing Preload

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Illustration 29 g00682033
Upper Pump Rotating Group
(B) Dimension that is determined by spacer (8)
( 40) Plates that determine bearing preload

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Illustration 30
c. g00683202
Lower Pump Rotating Group
(B) Dimension that is determined by spacer (8)
( 35) Plates that determine bearing preload

1. After the pump rotating groups have been assembled you must perform two primary
procedures. Complete the following procedures: Bearing preload and Lift-off Limitation.
Note: The bearing preload procedure that follows, pertains only to new bearings with
manufacture's lubricant.

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Illustration 31 g00682451

Note: Setting the bearing preload of the rotating group will require the use of bearing support
(K).
2. To fabricate bearing support (K), cut a 90 degree vee approximately 150 mm (5.9 inch) wide
into a block of wood. Call this dimension (C).

3. This wood block will be used to hold the rotating group while the drive shaft is rotated.

4. The following plates are used to adjust the bearing preload.

Table 4

Table for Plate (35) and (40) (1)

Plate Thickness (mm)

177-2491 2.6
177-2492 2.65
177-2493 2.70
177-2494 2.75
177-2495 2.80
177-2496 2.85
177-2497 2.90
177-2498 2.95
(1) Use the necessary plates (35) and (40) for adjusting the bearing preload on both rotating groups.

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Illustration 32 g00681982
5. Place the upper rotating group onto bearing support (K).

6. To check bearing preload, turn the M10 X 1.5THD bolt in the center of the upper rotating pump
group with a dial type torque wrench.
Rolling torque ... 3.75 ± 0.25 N·m (33.190 ± 2.213 lb in)

Illustration 33 g00682002

7. Place the lower rotating group onto bearing support (K).

8. To check bearing preload, turn the M16 X 2.00THD bolt in the center of the upper rotating pump
group with a dial type torque wrench.
Rolling torque ... 3.75 ± 0.25 N·m (33.190 ± 2.213 lb in)

Adjustment for Lift-Off Limitation (Cylinder Barrel To Port Plate

for Maximum Separation)
Reference: Refer to Tool Operating Manual, NEHS0699 -01 for completing this procedure.

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Illustration 34 g00907038

1. Align the timing marks on the rotating groups. The timing marks are at position (Z).

Illustration 35 g00526328

2. Heat the main pump housing to a temperature of 80 °C (176 °F). Install the upper pump
rotating group and the lower pump rotating group in both of the pump rotating group's original
locations in the main pump housing.

3. Make sure that the timing marks on each pump rotating group are in alignment with each other,
as shown.

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Illustration 36 g00682500
Retaining plate (12) is shown inverted. Final assembly the retaining plate must be flipped over.
4. Install both retaining plates (12) and centering pins (13).

Illustration 37 g00682571
The retaining plates are shown inverted. Final assembly the retaining plates must be flipped over.

5. Tighten socket head screws (11) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

6. Tooling (G) has several gauge plates. Select 187-6278 gauge plate for the pump.

Illustration 38 g00682512

7. Install three lead balls into the gauge plate, as shown.

8. Make sure that the lead ball is inserted into the large holes on the gauge plate. To keep the
lead balls from falling out of the gauge plate during installation, press on each lead ball with
your thumb.
Note: Do not crush the lead balls. Pressing the balls too deeply into the gauge plate will
provide inaccurate measurements.

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Illustration 39 g00682521
The retaining plates are shown inverted. Final assembly the retaining plates must be flipped over.
9. Place the gauge plate and the three lead balls on the centering pin (13).

Illustration 40 g00682536

10. Carefully place cylinder barrel (7) over the gauge plate and centering pin (13).
Note: Do not drop the cylinder barrel onto the centering pin. Dropping the cylinder barrel will
prematurely crush the lead balls. This will cause inaccurate measurements.

Illustration 41 g00682537

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11. Place cylinder barrel (7) over the gauge plate and centering pin (13).

Illustration 42 g00682542
(S) Suction side

12. Apply petroleum jelly under both port plates (6).

13. Place each port plate (6) into position on the pump control, as shown.

Illustration 43 g00689163

14. Install gasket (10) on the main pump housing.

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Illustration 44 g00633590
15. Fasten Tooling (B) and a hoist to the pump control (4).

16. Carefully install the pump control (4) on top of the main pump housing.
Note: If the pump control comes down hard onto the port plates, you should remove the pump
control. Then, verify that you have not damaged the lead balls. If the lead balls are damaged,
you should replace the lead balls. Then, reinstall the pump control.

17. Torque bolts (3) to 240 ± 40 N·m (175 ± 30 lb ft), while you turn the pump shaft.

18. Loosen and remove the previously installed socket head bolts (3).

Illustration 45 g00633590

19. Use Tooling (B) and a hoist to remove the pump control (4).

Illustration 46 g00682537

20. Remove the cylinder barrels (7).

21. Remove the gauge plate (G) with the lead balls.

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22. Determine the lift-off dimension, as follows.

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Illustration 47
023 38 g00682628

Cat
23. Measure all three lead balls and write down the average of the three. Call this Dimension (Z).

erp
Note: Keep each gauge plate with the respective rotating groups because you will have

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different lift-off dimensions for each rotating group.

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24. Use the following equation to determine the Lift-Off Limitation:
(Z) - 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
c.
25. Dimension (B) should equal the thickness of one of the spacers (8).
Table 5

Table for Spacer (8) (1)

Spacer Thickness (mm)

177-2509 12.3
177-2508 12.4
177-2507(2) 12.5
177-2506 12.6
177-2505 12.7
177-2504(2) 12.8
-(2) 12.9
-(2) 13.0
-(2) 13.1
-(2) 13.2
-(2) 13.3
-(2) 13.4

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(1) Use the necessary spacer (8) for setting the lift-off limitation for the upper pump rotating group and the lower
pump rotating group.
(2) Included in 247-8851 Spacer Kit

Reference: Refer to Illustrations 29 and 30 for dimension (B).

26. Make sure that you do not interchange the spacers, because the pump could be damaged
beyond repair.

Illustration 48 g00682571
The retaining plates are shown inverted. Final assembly the retaining plates must be flipped over.

27. Remove socket head screws (11) that hold the retaining plate and the centering pin.

Illustration 49 g00682500
Retaining plate (12) is shown inverted. Final assembly the retaining plates must be flipped over.

28. Remove both retaining plates (12) and centering pins (13).

29. Turn the main housing over 180 degrees.

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Illustration 50 g00640775
30. Install plug (19).

Illustration 51 g00684424

31. Install bearing (31) in the bearing's original position in the main pump housing. The bearing is a
slip fit.

Illustration 52 g00681619

32. Use a hammer to install key (29) into shaft (28).

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33. Heat gear (30) to a maximum temperature of 85 °C (185 °F).

34. Lower the temperature of shaft (28) to −40 °C (−40 °F).

35. Place the preheated gear in the main pump housing above bearing (27).

Illustration 53 g00681714

36. Install the cooled shaft through gear (30) and into bearing (31).
Note: Make sure that you align the woodruff key in shaft (28) with the corresponding slot in
gear (30).

37. Install bearing (27) on the shaft. Bearing (27) is a slip fit on the shaft.

Illustration 54 g00640813

38. Install three O-ring seals (26) to the pilot pump.

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Illustration 55 g00640803
39. Place pilot pump (24) in position in the main pump housing.

40. Install two bolts (25) that hold the pilot pump in position.

Illustration 56 g00681785

Illustration 57 g00684295

41. Position lip type seal (23) inside the main pump housing.

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Note: Use Tooling (J) to install the lip type seal (23) into the bore of the main housing. Drive the
seal slightly past the retaining ring groove in the main pump housing.
42. Make sure that the sealing lip is facing toward the inside of the main pump housing.

Illustration 58 g00640793

43. Install shim (22).

Illustration 59 g00640789

44. Use Tooling (D) and install retaining ring (21).

45. Turn the main pump housing over 180 degrees.

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Illustration 60 g00634154
46. Install two rings (16) on each piston (15).

Illustration 61 g00634149

47. Install pistons (14) in the piston's original locations in the pump rotating groups.

Illustration 62 g00634146

48. Install retaining plates (12) and centering pins (13) in the original positions over the pistons.
Make sure that the screw holes in the retaining plates are in alignment with the screw holes in

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the pump rotating groups.

Illustration 63 g00634140

Illustration 64 g07534434
49. Apply Tooling (K) on the threads of socket head screws (11).

50. Install the socket head screws to hold retaining plates (12) to the pump rotating groups. Tighten
the socket head screws evenly.

51. Install gasket (10).

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Illustration 65 g00634134
Note: Bevel spring washers (9) are not flat. These washers should be installed so that the
washers provide the maximum amount of height.
52. Install spacer (8) and four bevel spring washers (9) in each cylinder barrel (7).
Note: Use the spacer that was determined in Steps 2 through 26.

Illustration 66 g00684444
(7) Cylinder barrel
(8) Spacer
(9) Bevel washers

53. Install the bevel spring washers, as shown.

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Note: Apply petroleum jelly to bevel spring washers (9) and spacer (8) to prevent bevel spring
washers (9) and spacer (8) from falling out of barrel (7) during installation.

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023 38
54. Install two cylinder barrels (7) in the cylinder barrel's original locations on the pump rotating
groups.

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r In
c.

Illustration 68 g00685317

55. Install two dowels (5) in the main pump housing.

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Illustration 69 g00682542
(S) Suction side
56. Apply petroleum jelly under both port plates (6).

57. Place each port plate (6) into position on the pump control, as shown.

Illustration 70 g00633590

58. Fasten Tool (B) and a hoist to pump control (4), as shown. Place the pump control in position
on the main hydraulic pump.

59. Install socket head bolts (3) that hold the pump control to the main hydraulic pump.

Illustration 71 g00633959

60. Install the O-ring and plate (2) on the main pump housing.

61. Install the four socket head bolts that hold the plate in position.

62. Make sure that drain plug (1) is tight.

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Note: Bench test the pump. Refer to Special Instruction, NEHT5000, "Bench Testing Hydraulic
Components" for the correct procedure to bench test the main hydraulic pump.

End By:

a. Install the main hydraulic pump and the pump drive coupling.

PSP-0004D4CD
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22:24:55-06:00
i01773801
© 2023 Caterpillar Inc.

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