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 Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature 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 ............................
Hydraulic Pump - Assemble .................................
Cartridge Assembly - Disassemble .......................
Cartridge Assembly - Assemble ...........................

11
14
18
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 battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with
a battery disconnect switch, disconnect the battery cables from the battery and tape the battery
clamps.
Place a do not operate tag at the battery disconnect 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.

Illustration 1
Balanced cartridge

g00886749

5
Vane Pump
Systems Operation Section

g00886750

Illustration 2

4. Hydraulic fluid enters the pump through the front

body. Hydraulic fluid surrounds the cartridge on
the V model and the VQ model pumps. Fluid
flows into the cartridge through openings in the
inlet support plate and the cam ring. Fluid flows
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.

i01714319

Component Descriptions
SMCS Code: 5055

Illustration 3

g00886409

6
Vane Pump
Systems Operation Section

Illustration 4

g00888313

Illustration 6

g00886409

Illustration 7

g00888313

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.

Illustration 5

g00886457

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.

3. Pumps in the VQ model series contain the

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

7
Vane Pump
Systems Operation Section
Table 2

Torque Values
Series

Cover
Bolt

Housing
Bolt

Cover
Cartridge
Kit Screw

Shaft
Cartridge
Kit Screw

2520

61 6.8
Nm (45
5 lb ft)

95 6.8
Nm (70
5 lb ft)

41 6.8
Nm (30
5 lb ft)

61 6.8
Nm (45
5 lb ft)

3520

61 6.8
Nm (45
5 lb ft)

203
13.5 Nm
(150
10 lb ft)

41 6.8
Nm (30
5 lb ft)

142 6.8
Nm (105
5 lb ft)

3525

95 6.8
Nm (70
5 lb ft)

203
13.5 Nm
(150
10 lb ft)

61 6.8
Nm (45
5 lb ft)

142 6.8
Nm (105
5 lb ft)

4520

61 6.8
Nm (45
5 lb ft)

359
13.5 Nm
(265
10 lb ft)

41 6.8
Nm (30
5 lb ft)

142 6.8
Nm (105
5 lb ft)

4525

95 6.8
Nm (70
5 lb ft)

359
13.5 Nm
(265
10 lb ft)

61 6.8
Nm (45
5 lb ft)

142 6.8
Nm (105
5 lb ft)

4535

359
13.5
Nm
(265
10 lb ft)

****

142 6.8
Nm (105
5 lb ft)

142 6.8
Nm (105
5 lb ft)

g00886410

Illustration 8

4. The cartridge consists of the following

components:inlet support plate, outlet support
plate, two seal packs, two flex plates, cam ring,
slotted rotor, vanes, and intravanes.
Note: Replacement cartridges come with a bushing
in the inlet plate. The bushing is required in the top
cartridge of a double pump. Remove the bushing if
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

Illustration 9

25

203 13.5 Nm
(150 10 lb ft)

142 6.8 Nm
(105 5 lb ft)

35

203 13.5 Nm
(150 10 lb ft)

142 6.8 Nm
(105 5 lb ft)

2. Series code (2).

359 13.5 Nm
(265 10 lb ft)

142 6.8 Nm
(105 5 lb ft)

3. Shaft end flow (3) US GPM.

45

1. Viton seals (1).

4. Porting code (4).

5. Shaft code (5).
6. Outlet port code(6).
7. Design number (7).
8. Shaft rotation (8).

g00888241

8
Vane Pump
Systems Operation Section
9. Mounting (9).

Illustration 10

g00888242

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.

9
Vane Pump
Systems Operation Section
Table 3

Problem

Probable Cause

The pump
does not
deliver fluid.

Hydraulic line ruptured.

Inspect the hydraulic lines for ruptures. Replace the lines, as needed.

Air is leaking at the inlet.

Inspect all inlet connections for air leakage. Tighten any loose connections.

Leaking seals or missing

seals.

Replace the seals.

The inlet pipe in the reservoir

is restricted.

Inspect filters and strainers for dirt or sludge. Clean the filters or replace
the filters, as needed.

The pump will not prime. The

oil is the wrong viscosity.

Drain fluid from the system. Refill with new, filtered fluid of the proper
viscosity.

The pump is not pumping.

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.

The shaft is disengaged

or the shaft is shared. The
coupling is disengaged or
the coupling is shared.

Inspect couplings for damage. Replace couplings, as needed. Disassemble

the pump and inspect the shaft and the cartridge for damage.

The pump is driven in the

wrong direction of rotation.

In order to change the rotation of the pump, the pump must be shut down.

Vanes stuck in the rotor

slots.

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.

The system relief valve is

set too low.

Use a pressure gauge to adjust the relief valve setting.

Internal fluid loss

Inspect the system for possible fluid leakage. Replace any damaged parts.

The cartridge assembled for

wrong rotation.

Disassemble the pump and the cartridge. Reassemble the cartridge for the
proper direction of rotation.

The inlet lines are damaged

or the inlet lines are
reversed. The outlet lines
are damaged or the outlet
lines are reversed.

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.

The
system has
insufficient
pressure.

Possible Solution

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
noisy pump
operation

The fluid level is too low in

the reservoir.

Refill the reservoir to the proper level with new, filtered fluid.

Fluid in the system is too

thick.

Drain fluid from the system. Refill with new, filtered fluid of the proper
viscosity.

The inlet pipe is restricted in

the reservoir.

Inspect filters and strainers for dirt or sludge. Clean the filters or replace
the filters, as needed.

Air is present in the system.

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.

Overheated
pump

The inlet line is damaged

or the inlet line is reversed.
The outlet line is damaged
or the outlet line is reversed.

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.

Drive speed on the pump is

incorrect.

Ensure that the pump is operating above the minimum drive speed.

The coupling is Incorrectly

aligned on the shaft.

Inspect the shaft seals and bearing for damage. Replace parts, as needed.

Fluid is leaking within the

pump.

Inspect areas of leakage. Replace the damaged parts, as needed. Perform

a complete overhaul if the leakage is excessive.

The heat exchanger is

malfunctioning.

Inspect the heat exchanger for damage. Repair the heat exchanger, as
needed.

11
Vane Pump
Disassembly and Assembly Section

Disassembly and Assembly

Section

Note: All pumps are designed so changes in

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

i01716152

Note: Put alignment marks on the pump housing

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

1P-1859

Retaining Ring Pliers

1P-0510

Driver Gp

Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic
system.

Illustration 11

g00878060

1. Remove O-ring seal (2). Remove four bolts (1).

Make sure all of the attachments have been lowered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the engine 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, 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, 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: 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.

Illustration 12

g00878093

2. Separate body (3) and cover (5). Remove

cartridge assembly (4) from body (3).

12
Vane Pump
Disassembly and Assembly Section

Illustration 13

g00878097

3. Use Tool (A) to remove retaining ring (6). Remove

O-ring (7).
4. Remove shaft (8) and bearing (10) from body (3).

Illustration 15

g00878104

7. Remove lip seals (11) from body (3).

Double Vane Pump Disassembly

Procedure
Note: Pictures are typical examples.

Illustration 16

Illustration 14

g00878100

5. Remove ring (9).

6. Use a suitable press to remove bearing (10) from
shaft (8), as shown.

g00885309

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

cover (2) from body (3). Cartridge (5) will be
removed when cover (2) is removed.

13
Vane Pump
Disassembly and Assembly Section

Illustration 17

g00885310

2. Remove O-ring seal (4) from cover (2). Remove

cartridge (5) from cover (2).

Illustration 18

g00885311

3. Remove four bolts (6) from housing (7). Remove

housing (7) from body (3).

Illustration 19

g00885312

4. Remove O-ring seal (8) and cartridge (9) from

body (3).

Illustration 20

g00885313

5. Use Tool (A) to remove retaining ring (10) from

body (3).

Illustration 21

g00885314

6. Use a hydraulic press to remove shaft (11) from

body (3).

Illustration 22

g00885315

7. Remove outer retaining ring (12) from 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).

Illustration 25

g00878610

Illustration 26

g00878611

g00885317

Illustration 24

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

body (3).
i01716227

Hydraulic Pump - Assemble

SMCS Code: 5055

Single Vane Pump Assembly

Procedure
Table 5

Required Tools
Tool

Part
Number

Part Description

Qty

1P-1859 Retaining Ring Pliers

1P-0510 Driver Group

Note: Pump rotation is viewed from the shaft end.

Cartridges are normally assembled for right hand
rotation.

1. Use Tooling (B) to install lip seal (11) on the

inside of body (3). Install the lip seals with the
spring side of the lip seals toward the rear of the
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.

15
Vane Pump
Disassembly and Assembly Section

Illustration 27

g00878615

2. Turn body (3) onto the opposite side. Use Tooling

(B) to install lip seal (11) on the outside of body
(3). Make sure that the sealing lip is facing away
from the pump.

Illustration 29

g00878097

5. Install shaft (8) in body (3).

6. Install retaining ring (6) and O-ring (7).

Illustration 30

g00878093

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

Connect body (3) and cover (5).

Illustration 28

g00878622

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

Illustration 33

g00885316

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

Illustration 31

g00878060

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
for replacement. Apply clean oil to all internal
parts of the pump.

Illustration 32

Illustration 34

4. Install outer retaining ring (12) in body (3).

g00885317

2. Install lip seals (15) with Tool (C). Install O-ring

seal (16) to body (3). Install the lip seals with the
spring side of the lip seals toward the rear of the
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.

g00885315

Illustration 35

g00885324

5. Use a hydraulic press to install shaft (11) to

body (3). The seals need to be lubricated before
the installation of shaft (11).

17
Vane Pump
Disassembly and Assembly Section

Illustration 36

g00885313

6. Use Tool (A) to install retaining ring (10) to body

(3).

Illustration 37

g00885312

7. Install cartridge (9) and O-ring seal (8) to body

(3).

Illustration 38

g00885311

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

(6) to housing (7).

Illustration 39

g00885310

9. Install cartridge (5) to cover (2). Install O-ring

seal (4) to cover (2).

Illustration 40

g00885309

10. Install cover (2) to body (3). Install four bolts (1)
to cover (2).

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 pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic
system.
Make sure all of the attachments have been lowered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough
to touch with your bare hand.

Illustration 41

g00885330

Illustration 42

g00877566

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, 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
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.
1. Pump rotation is viewed from the shaft end.
Cartridges are normally assembled for right hand
rotation.

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).

19
Vane Pump
Disassembly and Assembly Section

Illustration 43

g00885331

4. Remove oil retainer seals (4) from inlet plate (3).

Illustration 44

g00885332

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

Illustration 45

g00885333

6. Remove ring (6) from flex plate (7).

Illustration 46

g00885334

7. Remove rotor (8) and vanes (9) from flex plate

(7).

20
Vane Pump
Disassembly and Assembly Section

Illustration 47

g00885335

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

Illustration 48

g00883128

22
Vane Pump
Disassembly and Assembly Section

Illustration 49

g00883127

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.

Illustration 50

Illustration 52

g00885334

Illustration 53

g00888319

g00877566

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).

Illustration 51

g00885335

24
Vane Pump
Disassembly and Assembly Section

Illustration 54

g00885333

6. Install ring (6) to flex plate (7).

Illustration 56

g00885331

8. Install seal (4) to plate (3).

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

Illustration 55

g00885332

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
D
Disassembly and Assembly Section...................... 11
G
General Information................................................. 4
H
Hydraulic Pump - Assemble ..................................
Double Vane Pump Assembly Procedure ..........
Single Vane Pump Assembly Procedure ...........
Hydraulic Pump - Disassemble .............................
Double Vane Pump Disassembly Procedure .....
Single Vane Pump Disassembly Procedure ......

14
16
14
11
12
11

I
Identity Information .................................................. 7
Important Safety Information ................................... 2
S
Systems Operation Section ..................................... 4
T
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.