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Hydraulic Gear Pumps & Motors

P30/31, P50/51, P75/76 Bearing Series

NEXUSTM is a trademark of Caterpillar® Inc

The first requirement of good maintenance on hydraulic equipment is a clean and tidy workstation. 2 .Pump and Motor Service Instructions General This service manual will familiarize you with single and multiple section gear units and the components. Use caution when gripping parts in a vise to avoid damage to machined surfaces. The location of each part and the proper method required for assembly and disassembly. Lint left on the bearing or bushing surfaces will cause damage to the unit and shorten life. we suggest you first read the complete manual and familiarize yourself with the steps required. To facilitate repair. Before assembly. is important to clean all parts and wipe them with a lint-less rag. Dirt is a main factor in a poor repair job of any hydraulic system. Check all replacement parts closely to assure no damage has occurred during shipping and handling.

8. 4. 2. 17. 6. 25. Seal Retainer Shaft Cover Check Valve Ring Seal Bearing Thrust Plate Pocket Seal Shaft & Gear Gasket 12 19. 5. 13. 23. 16. 22. 9. 27. 7. Carrier Connect Shaft Gear Set Port Cover Washer Bolt Nut Dowell Pin 11 13 4 7 6 5 8 10 13 3 2 1 P P UM 13 14 7 6 18 9 19 15 20 M O OT R 18 26 17 25 15 14 14 15 18 19 13 23 24 16 18 22 15 14 21 27 16 16 3 . 26. 24.Exploded View and Parts List 1. 14. 21. 12. Housing Brg. 18. 3. 15. 20. 11. Shaft Retainer Snap Ring Pump Seal Motor Seal Spirolock Bearing Pump Seal Motor Seal 10.

Gear Housing Life off gear housing taking care not to damage the machined surfaces.Disassembly – Series P30/31. Port End Cover Remove the caps screws and washers on single units or threaded rods on multiple units. This line will be used for realigning components during reassembly. P75/76 Step 1. Port End Cover Remove port end cover and thrust plates by inserting screw drivers or pry bars. P50/51. With a sharp metal scribing tool. Step 3. scribe a line a line down the pump from port end cover to shaft end cover. 4 . Gear Housing Remove the drive and idler gera taking care not to damage machined surfaces. Thrust plate and roller bearings will remain with the port end cover when removed as shown on far right. Port End Cover Mount the pump in a secure vise or mounting table (shaft end down). Be sure not to damage the machined surfaces. grease pencil or magic marker. Step 5. Be carefule to keep the gears together. Step 4. Remove thrust plate and examine for wear. Step 2. since they have worked-in together. You must reasemble them as pairs. Use screw drivers or pry bars as necessary.

NOTE: Wear Safety Goggles when working with Snap Rings. 5 . Shaft End Cover If you plan to replace the bearings. Bearing Carrier On multiple section units. Step 8. Gear Housing Lift off gear housing taking care not to damage the machined surfaces. or can be removed by hand. Check thrust plate for wear and flatness. Be careful to keep the gears together. P50/51. Use screw drivers or pry bars as necessary. Be careful not to damage the machined surfaces. Step 7. You must reassemble them as pairs.Disassembly – Series P30/31. Shaft End Cover Remove the drive and idler gear from shaft cover taking care not to damage machined surfaces. remove the connecting shaft. Bearings should remain in cover. Step 9. remove the bearing carrier. If they do not. Shaft End Cover Remove thrust plates and inspect them for excessive wear. Use screw drivers or pry bars as necessary. Step 11. since they have worked-in together. P75/76 Step 6. discard shaft end cover. Gear Housing On multiple sections units. turn shaft end cover over and remove the shaft bearing snap ring. Step 10.

Shaft End Cover Remove the ring seal and inspect mating surface in the cover for deep scoring (replace shaft end cover is necessary). NOTE: Reuse of ring seal is not recommended. P75/76 Step 12. Shaft End Cover Remove the shaft bearing from the shaft end cover with the proper tool. Step14. P50/51.Disassembly – Series P30/31. Step 13. Shaft End Cover Use a bearing puller to pull the roller bearings out of the shaft end cover. Take care not to damage the bearing seal. 6 .

Shaft End Cover Cut 2 seals from the seal strip 1/8” long. Shaft Cover Case Drain Plug Internal Dearings Ring Seal Shaft Bearing Check Valve Step 2. Shaft End Cover Insert drive gear using a seal protector. 7 . Insert the seal strip until it butts against the bearing. P75/76 Step 1.Assembly – Series P30/31. Maker sure the gear face contacts the thrust plate. Tap thrust plate with soft hammer until flush. back off 1/16” and cut. P50/51. Install idler gear in second bearing. your API shaft end cover has been preassembled with components shown on the far right. Repeat process for remaining three slots. High Pressure Seal Spirolock Ring Step 4. Shaft End Cover Secure shaft end cover in soft jaw vice or mounting table gear end up. Do not use hammer to install the shaft & gear. Step 3. Shaft End Cover To aid in assembly. Shaft End Cover Place thrust plate over the two roller bearings with the counter-bored side down to within 1/32” of the machined surface. grease them well and insert them into the center slots of the trust plate. Step 5.

Step 10. Gear Housing Grease second gasket well and insert into grove of gear housing. P75/76 Step 6. Make sure gaskets stay in place and are not pinched between machined surfaces. Step 8. Gear Housing Grease one of two gaskets well and insert into the grove the gear housing. P50/51. Bearing Carrier For multiple units.Assembly – Series P30/31. Bearing Carrier Housing Bearings Step 11. insert ring seal. The carrier consist of the parts shown on right. Turn over housing for next step. a bearing carrier is required. Bearing Carrier For multiple units. in thru hole of bearing carrier. Install dowel pins on one side of the housing. It may be necessary to use a soft hammer to aid in the installation. Install dowel pins in gear housing using a soft hammer if necessary. Ring Seals 8 . Gear Housing Place the gear housing over the gear set and tap down unit it meets the shaft end housing. Step 7. taper side up. Shaft End Cover Install dowel pins in shaft end cover. Step 9.

thrust plate side down. Step 16. Step 15. Step 14. install thrust plate on one side of bearing carrier using the same process to install the pocket seals in Step 3 & 4. Step 17. Bearing Carrier For multiple units. P50/51.Assembly – Series P30/31. in thru hole. Gear Housing For multiple units. grease one of the two gaskets well and insert into the groove of the second gear housing. Bearing Carrier For multiple units. Step 13. over the gear set and down onto the gear housing. Turn over the assembly. Insert the second ring seal. Install the next set of gears onto the connecting shaft making sure that the face of the gears make contact with the thrust plate. insert the connecting shaft into the rear of the spline of the drive gear. Bearing Carrier For multiple units. install the second thrust plate over the bearing inserting pocket seals as in Steps 3 & 4. Install remaining two bearings. install bearing carrier. Bearing Carrier For multiple units. P75/76 Step 12. Use only a soft hammer as needed. press two bearings in one side of bearing carrier. taper side up. Bearing Carrier For multiple units. 9 . install dowel pins in bearing carrier using a soft hammer as needed.

P50/51. Take care to asure gaskets remains in the grooves of the gear housing. Port End Cover Cut two seals from the seal strip 1/8” long. Step 23. Port End Cover The port end cover consists of the components shown on the immediate right and will need to be assembled as described in Steps 20 throught 22. 8 & 9 and place the gear housing over the gears making sure it contacts with the machined surface of the bearing carrier.Assembly – Series P30/31. grease them well and insert them into the center slots of the trust plate. Gear Housing For multiple units. taper side up. Port End Cover Press two roller bearings in the bores of the port end cover. Port End Cover Insert ring seal. Step 22. Step 21. Port End Cover Locate port end cover for hole with wider counter-bore as shown. 10 . P75/76 Step 18. Step 19. repeat Steps 7. Internal Bearings Rear Cover Ring Seal Step 20. into hole with wider counter-bore of port end cover. Take care not to cock or wedge between ring seal and bottom of counter-bore.

P75/76 Step 24. Place port end cover assembly over the gear hubs. Insert the seal strip until it butts against the bearing. Tap thrust plate with soft hammer until flush. Port End Cover For single units. Port End Cover For single units. install dowel pins in gear housing. Step 25. P50/51. in holes of port end cover. tap the port end cover assembly gentlydown on the housing with a soft mallet. Torque Specification – Series P30/31.000 PSI minimum tensile strength. use Grade 8 threaded rod with washers. Ft. tighten nuts to recommended torque. 200 200 11 .11 UNC-2A Thread Number Req’d 4 8 Torque Lb. Repeat process for remaining three slots.11 UNC-2A Thread 5/8 . The drive gear has longer bearing hubs to engge in the ring seal. P50/51. place screws with washers. P75/76 TABLE A Recommended Torque for Pumps & Motors Series P30 / 31 P50 / 51 P75 / 76 Size 5/8. for multiple units. Step 26. Step 27. tighten evenly and alternately with a torque wrench to recommended torque shown in Table A. Port End Cover Place thrust plate over the two roller bearings with the counter-bored side down to within 1/32” of the machined surface. Port End Cover For single or multiple units. or for multiple units. NOTE: All bolts or tie rods must be SAE Class 8 with 150.Assembly – Series P30/31. back off 1/16” and cut.

Raise the pressure to operating pressure in increments of 300 PSI. The feed line must provide a feed flow velocity not in excess of 8 feet per second. 2. 4. 2. 3. 12 . naphtha-based aircraft hydraulic fluids. no more than 5” Mercury Vac.500 RPM. 3. Always use an accurate pressure gauge when adjusting the pressure setting. Never use low viscosity. Always use an accurate pressure gauge when adjusting the maximum engine speed for the vehicle.Start-Up & Test Procedure 1. fill all ports with clean hydraulic oil to provide initial lubrication. as a rule. pausing at each setting for 20-30 seconds.P. This may cause the unit to seize. 7. Operate the pump for at least two minutes at ero pressure and not over 1. 5. Be sure that you have enough oil supply (at least 1 gallon of oil for each G. a 10% to 15% lower flow rate may be experienced and may be acceptable depending on the requirements of the unit. of pump capacity). The pump must be run in at low pressure (0-200 PSI) for 2 minutes before adjusting pressure settings. • Keep this oil clean and free of dirt. If testing a multiple unit. Hot oil must not be feed into a cold pump. Before starting a new or rebuilt pump. or automotive brake fluids. This is particularly important when a pump is located above the reservoir. • Temperature should not exceed 120°F for the test. Reset the main relief valve to its correct setting while the pump is operating at the maximum engine speed for the vehicle. This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recommended operation pressure. Before connecting any lines to the pump. The feed line must be of adequate size. make sure there is enough oil for all sections and sections not being tested have unobstructed lines going to the oil reservoir. Recommended Test Procedure 1. NOTE: If used parts are installed in the unit. back off the system relief valve until the spring tension on the adjusting screw is relieved. • Oils should be good quality – at least 150 SSU at 100°F. The flow of oil should run close to the rated flows found in the performance chart of the catalog.M. Gradually increase the pressure to the desired test pressure. 6. 4.

3 20 7.2 10 2. Housing Codes Series 30/31 5 7 10 12 15 17 20 22 25 27 30 Housing Codes Displacement (Cu In / Rev) Theoretical Flow (gpm) Assumed Efficiency Actual Flow (gpm) Series 50/51 05 0.89 35.6 13.1 05 Housing Codes Displacement (Cu In / Rev) Theoretical Flow (gpm) Assumed Efficiency Actual Flow (gpm) 30 11.8 22 25 27 30 Housing Codes 22 5.2 90% 9.7 90% 6.45 17.3 15 2.37 48.2 12 2.0 90% 26. it is recommended that they be tested as a pump and running them in both directions.75 19. 11. Reversing the direction will result in the shaft seal leaking and require replacement.7 12 4. Set speed to 1200 rpm and load to 100 psi.41 43.98 25.8 90% 11.14 16. 10.7 90% 21.4 54.97 10.Start-Up & Test Procedure Recommended Test Procedure (cont’d) 8.3 90% 29.3 90% 53.9 07 2.0 25 9.1 90% 11.65 29.56 23.99 5.1 22 8.48 7.9 90% 8.0 90% 16.96 15.4 90% 26. 13 .7 90% 43. After completing the test procedure.53 13.5 90% 18.1 17 4.21 32.4 9. Plug all ports to keep dirt and debris from entering the unit during handling.5 15 5.9 9. Make the unit run in the direction for which it was built.7 90% 39.4 90% 13.8 27 6.3 25 6.47 18.46 12.42 59. Flow should be greater than or equal to actual flow provided below.8 10 3.8 15 3.5 90% 12.4 17 3.9 90% 16. the unit is ready for installation.4 20 4.8 90% 6.3 Theoretical Flow (gpm) Assumed Efficiency Actual Flow (gpm) Series 75/76 6.6 30 Displacement (Cu In / Rev) 1.44 38.94 20.3 90% 14.2 10 1.37 22.8 90% 32.1 90% 4.0 90% 30.6 90% 34.6 20 3.6 05 07 1.2 27 10.59 29.9 07 1.9 90% 23.0 90% 48.5 12 3.4 17 6.5 90% 17. Since testing motors on a dynamometer is impractical.55 34.7 90% 20.

Troubleshooting Guide Possible Pump Trouble Aeration and Cavitation Noisy Pump Possible Cause Low Oil Supply Cold Oil Dirty Suction stratiner Suction Line Under-Sized Restriction in the Sucton Line Correction Required Fill to the proper level Replace with proper oil Clean or replace the strainer Increase line size Remove restriction in the line Pump takes too long or fails to response Low oil supply Insufficient relief valve pressure Pump worn or damaged Fill to proper level Reset the pressure Repair or replace pump Oil heating up Relief valve setting is to low Oil is to light Dirty oil Oil level low Reservoir capacity is too small Pump slippage Reset or replace valve Drain and fill with proper oil Drain flush/refill with clean oil Fill to proper level Install an oil cooler or change to proper size reservoir Repair or replace Oil foaming Air leak into suction line from tank to pump Wrong kind of oil Oil level low Improper hydraulic tank baffle Return line located above oil level Damaged or worn shaft on the pump Tighten all connections Drain and fill with proper oil Fill to proper level Rework baffle Install below the oil level Replace shaft seal low flow or pressure from the pump Damaged thrust plates Damaged check valve Worn gear housing Worn gear set Shaft seal introducing air to the pump Replace all thrust plates Replace all check valves Replace gear housing Replace the gear set Replace the shaft seal Pump shaft seal leaking Shaft area worn around seal area Check valve in pump not sealing Ring seal damaged or worn Case drain line not installed (motors) Replace the shaft Clean or replace check valve Replace ring seal Install drain line 14 .

NEXUSTM is a trademark of Caterpillar® Inc Media Number: PECJ0001-01 © 2004 Caterpillar .