RENR7451

June 2002

Systems Operation
Disassembly and
Assembly
Generic Vane Pump
9KW1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 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

Disassembly and Assembly Section

Hydraulic Pump - Disassemble ............................ 11
Hydraulic Pump - Assemble ................................. 14
Cartridge Assembly - Disassemble ....................... 18
Cartridge Assembly - Assemble ........................... 20

Index Section
Index ..................................................................... 25

Accidental machine starting can cause injury or

death to personnel working on the machine.

To avoid accidental machine starting, turn the bat-

tery disconnect switch to the OFF position and re-
move the key. If the machine is not equipped with
a battery disconnect switch, disconnect the bat-
tery cables from the battery and tape the battery
clamps.

Place a do not operate tag at the battery discon-

nect switch location to inform personnel that the
machine is being worked on.
4
Vane Pump
Systems Operation Section

Systems Operation Section

General Information
i01714271

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.

g00886749
Illustration 1
Balanced cartridge
 5
Vane Pump
Systems Operation Section

g00886750
Illustration 2

4. Hydraulic fluid enters the pump through the front i01714319

body. Hydraulic fluid surrounds the cartridge on
the V model and the VQ model pumps. Fluid Component Descriptions
flows into the cartridge through openings in the
inlet support plate and the cam ring. Fluid flows SMCS Code: 5055
into the cartridge through openings in the inlet
support plate and the flex plate in VQ models
and the cam ring. Fluid is discharged through
the flex plate VQ models and the outlet support
plate to the outlet port in the body.

g00886409
Illustration 3
6
Vane Pump
Systems Operation Section

g00888313 g00886409
Illustration 4 Illustration 6

1. Pumps in the V model series contain the following

components:rear cover, front body, shaft, and
cartridge. Double pumps have a inlet housing
(center housing) and two cartridges.

g00888313
Illustration 7

3. Pumps in the VQ model series contain the

following components:rear cover, front body,
shaft, and cartridge. Double pumps have a inlet
g00886457 housing (center housing) and two cartridges.
Illustration 5

2. The cartridge consists of the following

components:inlet support plate, outlet support
plate, cam ring, slotted rotor, vanes, and
intravanes. 2520, 3520, and 4520 contain a 20
series cartridge.
 7
Vane Pump
Systems Operation Section

Table 2
Torque Values
Series Cover Housing Cover Shaft
Bolt Bolt Cartridge Cartridge
Kit Screw Kit Screw
2520 61 ± 6.8 95 ± 6.8 41 ± 6.8 61 ± 6.8
N·m (45 N·m (70 N·m (30 ± N·m (45 ±
± 5 lb ft) ± 5 lb ft) 5 lb ft) 5 lb ft)
3520 61 ± 6.8 203 ± 41 ± 6.8 142 ± 6.8
N·m (45 13.5 N·m N·m (30 ± N·m (105
± 5 lb ft) (150 ± 5 lb ft) ± 5 lb ft)
10 lb ft)
3525 95 ± 6.8 203 ± 61 ± 6.8 142 ± 6.8
N·m (70 13.5 N·m N·m (45 ± N·m (105
± 5 lb ft) (150 ± 5 lb ft) ± 5 lb ft)
10 lb ft)
4520 61 ± 6.8 359 ± 41 ± 6.8 142 ± 6.8
N·m (45 13.5 N·m N·m (30 ± N·m (105
± 5 lb ft) (265 ± 5 lb ft) ± 5 lb ft)
g00886410 10 lb ft)
Illustration 8
4525 95 ± 6.8 359 ± 61 ± 6.8 142 ± 6.8
4. The cartridge consists of the following N·m (70 13.5 N·m N·m (45 ± N·m (105
components:inlet support plate, outlet support ± 5 lb ft) (265 ± 5 lb ft) ± 5 lb ft)
plate, two seal packs, two flex plates, cam ring, 10 lb ft)
slotted rotor, vanes, and intravanes. 4535 359 ± **** 142 ± 6.8 142 ± 6.8
13.5 N·m (105 N·m (105
Note: Replacement cartridges come with a bushing N·m ± 5 lb ft) ± 5 lb ft)
in the inlet plate. The bushing is required in the top (265 ±
cartridge of a double pump. Remove the bushing if 10 lb ft)
the cartridge is used elsewhere.

Note: Cartridges are pre-tested. Testing of groups

is not required.

i01714341

Identity Information
SMCS Code: 5055
Table 1
Torque Values
Series Cover Bolt Cartridge Kit Screw
g00888241
Illustration 9
25 203 ± 13.5 N·m 142 ± 6.8 N·m
(150 ± 10 lb ft) (105 ± 5 lb ft)
1. Viton seals (1).
35 203 ± 13.5 N·m 142 ± 6.8 N·m
(150 ± 10 lb ft) (105 ± 5 lb ft) 2. “Series code” (2).
45 359 ± 13.5 N·m 142 ± 6.8 N·m
(265 ± 10 lb ft) (105 ± 5 lb ft) 3. “Shaft end flow” (3) US GPM.

4. “Porting code” (4).

5. “Shaft code” (5).

6. “Outlet port code”(6).

7. “Design number” (7).

8. “Shaft rotation” (8).

8
Vane Pump
Systems Operation Section

9. “Mounting” (9).

g00888242
Illustration 10

10. Viton seals (1).

11. “Series code” (2).

12. “Shaft end flow” (3) US GPM.

13. “Porting code” (4).

14. “Cover end flow” (5).

15. “Shaft code” (6).

16. “Port position” (7).

17. “Design code” (8).

18. “Shaft rotation code” (9).

19. “Mounting” (10).

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.

Table 3
Problem Probable Cause
The pump Hydraulic line ruptured.
does not
deliver fluid. Air is leaking at the inlet.
Leaking seals or missing
seals.
The inlet pipe in the reservoir
is restricted.
The pump will not prime. The
oil is the wrong viscosity.
The pump is not pumping.
The shaft is disengaged
or the shaft is shared. The
coupling is disengaged or
the coupling is shared.
The pump is driven in the
wrong direction of rotation.
Vanes stuck in the rotor
slots.
The The system relief valve is
system has set too low.
insufficient
pressure. Internal fluid loss
The cartridge assembled for
wrong rotation.
The inlet lines are damaged
or the inlet lines are
reversed. The outlet lines
are damaged or the outlet
lines are reversed.
9
Vane Pump
Systems Operation Section
Possible Solution
Inspect the hydraulic lines for ruptures. Replace the lines, as needed.
Inspect all inlet connections for air leakage. Tighten any loose connections.
Replace the seals.
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.
Inspect couplings for damage. Replace couplings, as needed. Disassemble
the pump and inspect the shaft and the cartridge for damage.
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.
Use a pressure gauge to adjust the relief valve setting.
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.
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 The fluid level is too low in
noisy pump the reservoir.
operation
Fluid in the system is too
thick.
The inlet pipe is restricted in
the reservoir.
Air is present in the system.
The inlet line is damaged
or the inlet line is reversed.
The outlet line is damaged
or the outlet line is reversed.
Drive speed on the pump is
incorrect.
The coupling is Incorrectly
aligned on the shaft.
Overheated Fluid is leaking within the
pump pump.
The heat exchanger is
malfunctioning.
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.
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 areas of leakage. Replace the damaged parts, as needed. Perform
a complete overhaul if the leakage is excessive.
Inspect the heat exchanger for damage. Repair the heat exchanger, as
needed.
 11
Vane Pump
Disassembly and Assembly Section

Disassembly and Assembly Note: All pumps are designed so changes in

direction of rotation, port positions, and pumping
Section capacity are easily made.

Note: Put alignment marks on the pump housing

i01716152 prior to disassembly.
Hydraulic Pump - Disassemble Note: Pictures are typical examples.
SMCS Code: 5055

Single Vane Pump Disassembly

Procedure
Table 4
Required Tools
Tool Part Number Part Description Qty
A 1P-1859 Retaining Ring Pliers 1
B 1P-0510 Driver Gp 1

Personal injury can result from hydraulic oil pres-

sure and hot oil.

Hydraulic oil pressure can remain in the hydraulic

system after the engine has been stopped. Seri- g00878060
Illustration 11
ous injury can be caused if this pressure is not re-
leased before any service is done on the hydraulic
1. Remove O-ring seal (2). Remove four bolts (1).
system.

Make sure all of the attachments have been low-

ered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the en-
gine 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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. g00878093
Illustration 12
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 2. Separate body (3) and cover (5). Remove
suitable to collect and contain fluids on Caterpillar cartridge assembly (4) from body (3).
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.
12
Vane Pump
Disassembly and Assembly Section

g00878097 g00878104
Illustration 13 Illustration 15

3. Use Tool (A) to remove retaining ring (6). Remove 7. Remove lip seals (11) from body (3).
O-ring (7).

4. Remove shaft (8) and bearing (10) from body (3).

Double Vane Pump Disassembly
Procedure
Note: Pictures are typical examples.

g00885309
Illustration 16

1. Remove four bolts (1) from cover (2). Remove

g00878100 cover (2) from body (3). Cartridge (5) will be
Illustration 14 removed when cover (2) is removed.
5. Remove ring (9).

6. Use a suitable press to remove bearing (10) from

shaft (8), as shown.
 13
Vane Pump
Disassembly and Assembly Section

g00885310 g00885313
Illustration 17 Illustration 20

2. Remove O-ring seal (4) from cover (2). Remove 5. Use Tool (A) to remove retaining ring (10) from
cartridge (5) from cover (2). body (3).

g00885311 g00885314
Illustration 18 Illustration 21

3. Remove four bolts (6) from housing (7). Remove 6. Use a hydraulic press to remove shaft (11) from
housing (7) from body (3). body (3).

g00885312 g00885315
Illustration 19 Illustration 22

4. Remove O-ring seal (8) and cartridge (9) from 7. Remove outer retaining ring (12) from body (3).
body (3).
14
Vane Pump
Disassembly and Assembly Section

Note: Pictures are typical examples.

g00885316
Illustration 23

8. Remove bearing (13) and washer (14) from body

(3).

g00878610
Illustration 25

g00885317
Illustration 24

9. Remove lip seals (15) and O-ring seal (16) from

body (3).

i01716227

Hydraulic Pump - Assemble

SMCS Code: 5055
g00878611
Illustration 26
Single Vane Pump Assembly
Procedure 1. Use Tooling (B) to install lip seal (11) on the
inside of body (3). Install the lip seals with the
Table 5 spring side of the lip seals toward the rear of the
Required Tools body. Install the inner lip seal until the lip seal is
seated in the body. Install the outer lip seal until
Part the lip seal is seated against the inner lip seal.
Tool Number Part Description Qty
A 1P-1859 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1

Note: Pump rotation is viewed from the shaft end.

Cartridges are normally assembled for right hand
rotation.
 15
Vane Pump
Disassembly and Assembly Section

g00878615 g00878097
Illustration 27 Illustration 29

2. Turn body (3) onto the opposite side. Use Tooling 5. Install shaft (8) in body (3).
(B) to install lip seal (11) on the outside of body
(3). Make sure that the sealing lip is facing away 6. Install retaining ring (6) and O-ring (7).
from the pump.

g00878093
Illustration 30

7. Install cartridge assembly (4) to body (3).

Connect body (3) and cover (5).

g00878622
Illustration 28

3. Heat bearing (10) to a maximum temperature of

135C (275F) for one hour. Install bearing (10)
onto shaft (8).

4. Install retaining ring (9).

16
Vane Pump
Disassembly and Assembly Section

g00885316
Illustration 33

3. Install washer (14) and bearing (13) to body (3).

g00878060
Illustration 31

8. Install O-ring seal (2). Install bolts (1).

Double Vane Pump Assembly

Procedure
Note: Pictures are typical examples.

1. Clean all parts and inspect all parts. If any parts

are worn or damaged, use a new Caterpillar part g00885315
Illustration 34
for replacement. Apply clean oil to all internal
parts of the pump. 4. Install outer retaining ring (12) in body (3).

g00885317
Illustration 32 g00885324
Illustration 35

2. Install lip seals (15) with Tool (C). Install O-ring 5. Use a hydraulic press to install shaft (11) to
seal (16) to body (3). Install the lip seals with the
body (3). The seals need to be lubricated before
spring side of the lip seals toward the rear of the
the installation of shaft (11).
body. Install the inner lip seal until the lip seal is
seated in the body. Install the outer lip seal until
the lip seal is seated against the inner lip seal.
 17
Vane Pump
Disassembly and Assembly Section

g00885313 g00885310
Illustration 36 Illustration 39

6. Use Tool (A) to install retaining ring (10) to body 9. Install cartridge (5) to cover (2). Install O-ring
(3). seal (4) to cover (2).

g00885312 g00885309
Illustration 37 Illustration 40

7. Install cartridge (9) and O-ring seal (8) to body 10. Install cover (2) to body (3). Install four bolts (1)
(3). to cover (2).

g00885311
Illustration 38

8. Install housing (7) to body (3). Install four bolts

(6) to housing (7).
18
Vane Pump
Disassembly and Assembly Section

i01716649 2. Reverse the rotation of a new cartridge.

Cartridge Assembly -
Disassemble
SMCS Code: 5055

Disassembly Procedure

Personal injury can result from hydraulic oil pres-

sure and hot oil.

Hydraulic oil pressure can remain in the hydraulic

system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not re-
leased before any service is done on the hydraulic
system.

Make sure all of the attachments have been low-

ered, oil is cool before removing any components g00885330
Illustration 41
or lines. Remove the oil filler cap only when the en-
gine 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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent 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 Illustration 42

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.
g00877566
Note: Put an alignment mark across the cartridge
for installation purposes. Note the direction of the
arrows at locations (X) and (Y). The arrows indicate
the direction of rotation for the pump.
3. Remove two bolts (2) from inlet plate (3). Remove
inlet plate (3) from cartridge (1).

1. Pump rotation is viewed from the shaft end.

Cartridges are normally assembled for right hand
rotation.
 19
Vane Pump
Disassembly and Assembly Section

g00885331 g00885333
Illustration 43 Illustration 45

4. Remove oil retainer seals (4) from inlet plate (3). 6. Remove ring (6) from flex plate (7).

g00885332 g00885334
Illustration 44 Illustration 46

Note: In the V model pumps, the configuration of 7. Remove rotor (8) and vanes (9) from flex plate
the flex plate is incorporated into the inlet support (7).
plate and into the outlet support plate. In VQ model
pumps, the flex plates are separate components.

5. Remove flex plate (5) from ring (6).

20
Vane Pump
Disassembly and Assembly Section

g00885335
Illustration 47

8. Remove flex plate (7) from outlet plate (10).

i01716452

Cartridge Assembly -
Assemble
SMCS Code: 5055

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

g00883128
Illustration 48
22
Vane Pump
Disassembly and Assembly Section

g00883127
Illustration 49
 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
Note: In the V model pumps, the configuration of
the flex plate is incorporated into the inlet support
plate and into the outlet support plate. In VQ model
pumps, the flex plates are separate components.
4. Install flex plate (7) to outlet plate (10). The
bronze face of the flex plate must be facing
toward the rotor.

• 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.

g00885334
Illustration 52

g00877566
Illustration 50

g00888319
Illustration 53

Note: The vanes must be installed so that the

leading edge is facing toward the direction of travel.

5. Install rotor (8) and vanes (9) to flex plate (7).

g00885335
Illustration 51
24
Vane Pump
Disassembly and Assembly Section

g00885333 g00885331
Illustration 54 Illustration 56

6. Install ring (6) to flex plate (7). 8. Install seal (4) to plate (3).

9. Install inlet plate (3) to cartridge (1). Install bolts

(2) to inlet plate (3).

g00885332
Illustration 55

7. Install flex plate (5) to ring (6). The bronze face

of the flex plate must be facing toward the rotor.
 25
Vane Pump
Index Section

Index
C

Cartridge Assembly - Assemble ............................ 20

Assembly Procedure.......................................... 20
Cartridge Assembly - Disassemble ....................... 18
Disassembly Procedure ..................................... 18
Component Descriptions ......................................... 5

Disassembly and Assembly Section...................... 11

General Information................................................. 4

Hydraulic Pump - Assemble .................................. 14

Double Vane Pump Assembly Procedure .......... 16
Single Vane Pump Assembly Procedure ........... 14
Hydraulic Pump - Disassemble ............................. 11
Double Vane Pump Disassembly Procedure ..... 12
Single Vane Pump Disassembly Procedure ...... 11

Identity Information .................................................. 7

Important Safety Information ................................... 2

Systems Operation Section ..................................... 4

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.