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Bench Test Procedures

Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic Pumps and
Motors {3203, 4351, 5058, 5070}
Media Number -REHS1607-14 Publication Date -13/04/2015 Date Updated -21/11/2016

i06875890

Rotating Group Adjustment Instructions for Bosch Rexroth

Hydraulic Pumps and Motors {3203, 4351, 5058, 5070}
SMCS - 3203; 4351; 5058; 5070

Agricultural Tractor
All
Armored Face Conveyor
All
Articulated Truck
All
Articulated Truck with Jake Brake Retarders Built Prior to 1999
All
Asphalt Paver
All
Backhoe Loader
All
Beamed Stageloader
All
Challenger
All
Cold Planer
All
Combine
All
Compact Track Loader
All
Compact Wheel Loader
All
Continuous Haulage
All
Continuous Miner
All
Dragline
All
Earthmoving Compactor
All
Electric Rope Shovel
All
Excavator
All

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Face Haulage
All
Feeder Breaker
All
Forest Products
All
Highwall Miner
HW 300 (S/N: HWM1-UP)
Hydraulic Shovel
All
Integrated Toolcarrier
All
Landfill Compactor
All
Load Haul Dump
All
Expanded Mining
Mini Hydraulic Excavator
All
Motor Grader
All
Multi Terrain Loader
All
Off-Highway Truck/Tractor
All
Paving Compactor
All
Pipelayer
All
Plow
All
Rock Feeder
RF300 (S/N: RF41-UP)
Rock Mover
RM900 (S/N: RF31-UP)
Roof Bolter
All
Roof Support Carrier
All
Roof Support
All
Rotary Drill
All
Scoop
ALL
Shearer
All
Skid Steer Loader
All

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Soil Compactor
All
Telehandler
All
Track Drills
All
Track Feller Buncher
Caterpillar
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Unit Rig Mining Truck
All
Wheel Dozer
All
Wheel Feller Buncher
All
Caterpillar Branded
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All
Wheeled Excavator
All

Introduction
Table 1
Revision Summary of Changes in REHS1607
14 Updated document to include A11VO 95cc values.
13 Updated Effectivity.
12 Updated Off-Highway Truck/Tractor effectivity.
11 Updated Illustration 22 .
10 Added new procedure "Bearing Preload Adjustment - A6VM 200 cc".
Added part number 437-5508 Plug for A11 145cc pump to "Lift-Off Clearance
09
Adjustment - A11VO/A11VLO" section of document.

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Changed title from "Rotating Group Adjustment Instructions for Bosch Rexroth Pumps
and Motors" to "Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic
08 Pumps and Motors".
Added "Important Safety Information".
Added part number 372-6543 Gauge Plate for A8 107cc pump to "Lift-Off Clearance
Adjustment - A8VO" section of document.
07 Added part number 372-6544 Gauge Plate for A8 200 cc pump to "Lift-Off Clearance
Adjustment - A8VO" section of document.
Added "Important Safety Information" section to document.
Made Major changes to "Lift-Off Clearance Adjustment - A6VM/A6VE 200/250/355
cc with the Type 2 Barrel" and "Lift-Off Clearance Adjustment - A8VO" sections.
Added part number 272-1417 Gauge Plate for A8 160 cc pump to "Lift-Off Clearance
Adjustment - A8VO" section of document.
Removed part number 149-4932 Gauge Plate for A8 160 cc pump from "Lift-Off
06
Clearance Adjustment - A8VO" section of document.
Removed part number 149-4931 Gauge Plate for A8 107 cc pump from "Lift-Off
Clearance Adjustment - A8VO" section of document.
Removed part number 187-6278 Gauge Plate for A8 200 cc pump from "Lift-Off
Clearance Adjustment - A8VO" section of document.

© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat Dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to
benefit from cost reductions. Every effort has been made to provide the most current information that
is known to Caterpillar. Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication. This Reuse and Salvage
Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator
(TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for
feedback in the Service Information System (SIS Web) interface.

This special instruction standardizes the instructions for the adjustment of the rotating group for
Bosch Rexroth hydraulic piston pumps and motors. This document will be a source to find the
instructions for the adjustment of the rotating group for all Caterpillar equipment that incorporates
Bosch Rexroth hydraulic piston pumps and motors.

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Summary
This special instruction standardizes the instructions for the adjustment of the rotating group for
Bosch Rexroth hydraulic piston pumps and motors. This document will be a source to find the
instructions for the adjustment of the rotating group for all Caterpillar equipment that incorporates
Bosch Rexroth hydraulic piston pumps and motors.

Important Safety Information

View Image

Illustration 1 g02139237

Work safely. 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. Safety precautions and warnings are provided in this instruction and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically
recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to
use. Ensure that the product will not be damaged or the product will not be made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are used.

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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 which is followed by a signal word such as
danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
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Illustration 2 g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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The message that appears under the safety alert symbol explains the hazard.

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 safety information in this document and the safety information on the machine are not all
inclusive. You must determine that the tools, procedures, work methods, and operating
techniques are safe. You must determine that the operation, lubrication, maintenance, and
repair procedures will not damage the machine. Also, you must determine that the operation,
lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. 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, most current information before
you start any job. Caterpillar dealers can supply the most current information.

Canceled Part Numbers and Replaced Part Numbers

This document may not include all Canceled part numbers and replaced part numbers. Use NPR on
SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts.

Type Code Breakdown

Pumps manufactured by Bosch Rexroth may be labeled several different ways including:
Brueninghaus Hydromatik GMBD, Mannesmann Rexroth, Rexroth Corp. the Mobile Hydraulic
Division, Rexroth-Sigma, or Uchida Hydraulics Co. LTD. Bosch Rexroth has a group of numbers and
letters attached to each pump known as pump identification or a pump description. The typical pump
or motor description can be broken down as follows:

Table 2
1 2 3 4 5 6 7 8 9
Type Code A20 V L O 60 EP / 61 R V

(1) Axial Piston Unit Family

A - Metric version

AA - SAE version

(2) Displacement Type

V - Variable Displacement

F - Fixed Displacement

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(3) L if Long Life Bearings, else no designation

Note: For A11 pumps, L designates with charge pump, else no designation

(4) Device and Style

M - Motor Standard Design

E - Motor Plug-In Design

G - Closed Circuit Pump

O - Open Circuit Pump

(5) Displacement in cubic centimeters

(6) Control Device

(7) Series and Index

(8) Direction of Rotation

R - Clockwise

L - Counterclockwise

W - Alternating

Note: View from the shaft end

(9) Seal Type

V - FPM Fluoro rubber

P - NBR Nitrile rubber

N - NBR, shaft seal in FPM

Document Coverage
Due to the extensive use of Bosch Rexroth pumps and motors in Caterpillar Equipment, it would not
be feasible to list all of the associated Caterpillar part numbers. The identification refers to the family
of the motor or pump, the displacement in cubic centimeters, and the series.

Table 3
Document Coverage
Family, Device, and Style Displacement in cc Series and Index
A2FM 16 to 180 Series 61

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A2FE 45 to 125 Series 61

A2FO 45 Series 61
A4VG 40 to 250 Series 32
A4VG 250 Series 10
A6VM 55 Series 60
A6VM 55 to 355 Series 63
A6VE 28 to 107 Series 63
A8VO 107 to 200 Series 60
A11VO 130 to 260 Series 10/11
A11VLO 130 to 260 Series 10
A20VLO 190 to 260 Series 10

Note: The A10 series of pumps requires no adjustment of the rotary group.

Fabricated Tooling
Certain tooling must be fabricated to perform adjustments to the rotating group for all pumps and
motors.

V-Block

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Illustration 3 g01009274
Tooling for the A2FM/A2FE/A2FO/A8VO pump and motor adjustment for the bearing preload.

1. To fabricate V-Block, cut a 90 degree vee approximately 150 mm (5.9 inch) wide into a block
of wood. Call this dimension (A).

Measuring Plate Group

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Illustration 4 g01009308
FT2739 Measuring Plate Group
Tooling for the 28-160 cc A2FM/A2FE/A2FO pump and motor adjustment for the lift-off clearance.
(1) 6V-4832 Screw
(2) 126-7181 Sliding Plate
(3) 1P-0456 Drive Plate
(4) 6V-3009 Cross Bar

1. Fabricate the measuring plate by constructing the 6V-3009 Cross Bar per instructions in print.

2. Refer to Illustration 4 to assemble the plate group components.

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Illustration 5 g01009306
FT2786 Measuring Plate Group
Tooling for the adjustment for the lift-off clearance for the A2FM/A2FE/A2FO 180-250 cc motors and pumps.
(5) 5P-8715 Forcing Bolt
(6) 5B-0637 Nut
(7) 3H-0465 Puller Plate
(8) 1U-9895 Crossblock
(9) 1P-0456 Drive Plate
(10) FT2786 Measuring Plate Group

1. Fabricate the measuring plate by constructing the FT2786 Measuring Plate Group per
instructions in print.

2. Refer to Illustration 5 to assemble the plate group components.

Rotating Group Adjustments

A2FM/A2FE Motors and A2FO Pumps for "Old Style" with a Spanner Nut

Old style A2FM/A2FE motors and A2FO pumps require a spanner nut to set the bearing preload and
the rotating torques. Cup springs and a shim are used to set the "lift off" clearance between the barrel
and the port plate. New style A2FM/A2FE motors and A2FO pumps use a snap ring for the bearing
preload and a center spring for the "lift-off" clearance.
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Illustration 6 g01118952
"Old Style" A2FM/A2FE Motor and A2FO Pump
(1) Spanner nut
(2) Cup springs

Bearing Preload Adjustment for the A2FM/A2FE/A2FO "Old Style"

This section shows the proper way to set the bearing preload. If bearing preload is too high or low,
bearing life will be shortened due to heat generation. Additionally, if bearing preload is too high the
rotating torque will be too high causing poor system operation.
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Illustration 7 g01011046
Bearing group of the "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut
(3) Bolt
(4) Upper Bearing
(5) Lower Bearing

1. Install both bearings (4) and (5) onto the shaft.

2. Place the spanner nut on the shaft. Tighten the spanner nut by using a spanner nut wrench.

3. Place a hex head bolt (3) in the shaft end.

4. Place the shaft group in the fabricated V-Block as shown in Illustration 8

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Illustration 8 g01012576

5. Place 9S-7354 dial type torque wrench on the installed bolt. Hold bearing outer races with a
hand to prevent rotation. Turn the shaft assembly. Observe the torque that is required to turn the
shaft assembly. Compare this value with the values from Table 4.

6. Adjust the spanner nut to set the required rotating torque.

7. Remove the bolt from the shaft end.

Table 4
Bearing Preload
Piston Diameter in mm (in) Displacement in cc Rotating torque in Nm (in-lb)
11.2 (0.441) 16 0.10-0.18 (0.89-1.59)
13.3 (0.524) 28 0.22-0.35 (1.95-3.10)
16 (0.630) 45 0.37-0.55 (3.27-4.87)
16.8 (.661) 56 0.45-0.70 (3.98-6.20)
17.8 (0.701) 63 0.45-0.70 (3.98-6.20)
18.9 (0.744) 80 0.75-1.10 (6.64-9.74)
20 (0.787) 90 0.75-1.10 (6.64-9.74)

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20.6 (0.811) 107 1.10-1.50 (9.74-13.28)

22.3 (0.878) 125 1.10-1.50 (9.74-13.28)
23 (0.906) 131 1.10-1.50 (9.74-13.28)
23.6 (0.930) 160 1.50-1.90 (13.28-16.82)
25 (0.984) 180 1.50-1.90 (13.28-16.82)

Rotating Group Positioning for the A2FM/A2FE/A2FO "Old Style"

View Image

Illustration 9 g01118959
Bearing group of "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut
(6) Snap ring
(7) Front cover
(8) Shim

1. Place cover (7) on shaft assembly.

Note: Measure without the adjustment shim (8)

2. Measure the distance (A) from the face of the shaft to the top of the cover.

Note: Do not include the shaft boss in measurements.

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3. Measure the thickness (B) of the snap ring (6).

4. Use dimension (C) from the Table 5 minus measured dimension (A). Then subtract measured
dimension (B) from that figure. The result is the required thickness of the shim (8). Refer to
Table 6 for the shim sizes and the associated part number.

Dimension (C) - dimension (A) - dimension (B) = required shim thickness.

Note: Multiple shim combinations may be used to achieve the desired dimension (C).

Table 5
Rotating Group Positioning
Displacement in cc Dimension (C) in mm (in)
16 76.6-76.7 (3.016-3.020)
28 76.8-76.9 (3.024-3.028)
45 83.2-83.3 (3.276-3.280)
56 89.6-89.7 (3.528-3.531)
63 89.6-89.7 (3.528-3.531)
80 99.4-99.5 (3.913-3.917)
90 99.4-99.5 (3.913-3.917)
107 111.2-111.3 (4.378-4.382)
125 111.2-111.3 (4.378-4.382)
131 111.2-111.3 (4.378-4.382)
160 120.7-120.8 (4.752-4.756)
180 120.7-120.8 (4.752-4.756)

Table 6
Adjustment Shim (8)
Displacement in cc Shim thickness in mm (in) Part Number
0.1 (0.004) 144-7804
16
0.3 (0.012) 144-7805
28
0.1 (0.004) 180-1376
45
0.3 (0.012) 180-1375

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0.1 (0.004) 9T-2904

56
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2904
63
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2582
80
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-2582
90
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-1576
107
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576
125
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576
131
0.3 (0.012) 9T-1579
0.2 (0.008) 6E-1704
160
0.3 (0.012) 6E-1705
0.2 (0.008) 6E-1704
180
0.3 (0.012) 6E-1705

Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "Old Style"

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off"
clearance or the allowable separation can be adjusted by adding or removing shims from the spring
cup group in the center pin bore. Excessive leakage will occur during high-pressure spikes which may
lead to rotary group damage and poor system performance if the allowable separation is too large.
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Illustration 10 g01139759
The typical lift-off clearance (F) measurement
(2) Cup spring set
(9) Port plate
(10) Housing
(11) Adjustment shim
(12) Barrel
(13) Center pin
(14) Measuring plate group
(15) Piston retaining plate
(16) Drive plates (3)

1. Insert the center pin (13). Insert the pistons. Attach the piston retaining plate (15) to the shaft
group.

2. The retaining plate (15) bolts need to be tightened to the specified torque value.

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