GEAR-SUN 2819323 - Caterpillar

Image1.1.1
INSPECTION OF RETAINER PLATE CONTAINMENT BOLTS
(Refer to Images 1.2.1 and 1.2.2 for details)
1. With the pump housing assembly oriented so the driveshaft is in vertical position, locate the swash plate at approximately the zero angle position (horizontal) to facilitate access to the retainer plate bolts.
2. Verify the torque on all four 6V-5192 Retainer Plate Containment Bolts by gradually applying force to a Dial Type Torque Wrench up to a minimum torque threshold of 17.0 ft-lb (23.0 Nm). The torque should be applied in a clockwise or tightening direction.
3. If the 6V-5192 Bolts do not turn until a minimum threshold of 17.0 ft-lb (23.0 Nm) torque is met, then they should be tightened to the recommended torque of 23.0-27.0 ft-lb (31.2-36.6 Nm) at which point the pump can be placed back in service. Please record pump serial number on the warranty claim.
4. If any of the 6V-5192 Bolts begin to turn at a torque below 17.0 ft-lb (23.0 Nm), the pump is not acceptable for use and must be returned to Caterpillar. Refer to the attached Parts Disposition within the service letter for shipping information.
Image1.2.1
Image1.2.2
PUMP REASSEMBLY
1. Visually inspect Housing Gasket (100-3413) and Gasket Surface for damage. If any defects are present reassemble the pump and return to Caterpillar.
2. Re-Install the 119-6224 Head/End-Cover by liberally applying heavy grease or petroleum jelly on valve plate and place valve plate on end cover, taking care to ensure the 9T-1652 Dowel Alignment Pin is properly engaged. Apply grease to 100-3415 Control Piston and place control piston on guide rods. Verify the 100-3409 Bias Piston Spring is installed properly under the 100-3408 Bias Piston.
Note: Guide Rods greatly simplify the assembly of the end cover to the housing. Pump assembly guide rods can be constructed by removing the heads from two M12 x 150MM bolts. Before proceeding secure two guide rods. (See Illustration 1.3.1, Guide Rods).
Image1.3.1
3. Position the pump housing in a horizontal position as shown in figure 1.4.1. Stabilize the shaft during reassembly, with the pump shaft horizontal. Take great care to maintain the driveshaft in a position tightly against the front bearing to protect the shaft seal and maintain alignment with the rear bearing during reassembly. Position the end cover on the alignment rods and slide the end cover assembly into place. Confirm the 100-3409 Bias Spring and 100-3408 Bias Piston are in place against the yoke subassembly at the conclusion of the placement process. If the valve plate slips, remove and apply a liberal amount of heavy grease or petroleum jelly to hold in place and reassemble.
Image1.4.1
4. Install two end cover bolts to snug head against body and turn the driveshaft by hand to confirm there is no binding and the bearings are properly seated. POSITION THE PUMP TO VERTICAL ORIENTATION. Install 2) 6V-8004, 2) 8T-0372 and 2) 259-7060 Head/End-Cover Bolts hand tight and draw the end cover and housing gap closed. (AIR GUNS NOT PERMITTED ? BOLTS MUST BE MADE SNUG BY MANUALLY TURNING) Prior to full application of end cover