8051-8078 Gearbox Data Sheet
Contents
1. Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1700 RPM 1700 RPM Maximum Engine RPM 3465 RPM 3465 RPM BOr eaa E e ee 0 551 14 mm xHorsepower Electric 15 4 HP 15 4 HP Stroken A 0 945 24 mm Pump Crankcase Capacity 25 OZ 0 75 L Weight merenna 43 6 Ibs 19 8 kg Dimensions with G B 14 02 x 10 75 x 8 19 356 x 273 x 208 mm See Model 70 data sheet for pump information x Standard Electric Brake Horsepower Requirement provided Consult Gas Engine Mfr for gas horsepower equivalent EXPLODED VIEW DIRECT DRIVE February 2005 GEARBOX MODELS 8051 8058 8061 8065 8068 8071 8078 505 506 507 506 507 524 PARTS LIST Item PartNo Description Gearbox Pump Model Qty Item PartNo Description Gearbox Pump Model Qty 8051 Gearbox Helical 1 Shaft 5 58 1 517 45933 Flange Bearing Cover 34 35 1 8058 Gearbox Helical 1 1 8 Shaft 51 58 1 45934 Flange Bearing Cover 51 58 59 60 70 1 8061 Gearbox Helical 1 Shaft 34 353 1 46122 Flange Bearing Cover M8 4 1 8065 Gearbox Helical 1 Shaft 4 1 518 210619 Lockwasher Conical M6 34 35 51 56 58 59 60 70 4 8 8068 Gearbox Helical 1 1 8 Shaft 34 35 1 46123 Lock2. PUMP FEATURES e Polished solid ceramic plungers last long and resist abrasion e Triplex plunger design providing low pulsation and quiet operation e Internally lubricated and cooled packings for extended life GEARBOX UNIT FEATURES e No pulley selection or adjustment for quick easy gas engine mounting e Totally sealed housing providing independent gearbox lubrication for maximum service life e Hardened steel helical design gears for smooth quiet operation e Multiple engine shaft and flange options for flexibility Direct Drive Gearbox Models 8051 8058 Used on Models 51 and 58 Pumps Models 8061 8068 Used on Models 34 and 35 Pumps Model 8065 Used on Model 45 Pumps Models 807 1 8078 Used on Models 56 59 60 70 Pumps COMMON SPECIFICATIONS U S Measure Metric Measure Gear Ratio 2 0384 to 1 2 0384 to 1 Mounting Face ccccccee 6 1 2 165 mm Engine Shaft Diameter EEE T E TE 1 25 4 mm IEE E AEE E AOE 1 1 8 28 5 mm Engine Shaft Length 3 1 4 82 6 mm Gearbox Capacity 10 oz 0 30 L Weight 8051 8058 8061 8065 8068 4 2 lbs 1 90 kg 8071 BOTS naimisiin 7 5 Ibs 3 40 kg DIMENSIONS cccceseeeeeeeee eee 6 42 x 4 53 x8 19 163x115x208 mm Customer confidence is our greatest asset SPECIFICATIONS Model 34G1 34 Pump 8061 G B Model 34G118 34 Pump 8068 G B U S Measure Metric Measure POWs i cs cccieretaee o
3. 71 50 Fax 32 3 450 71 51 7 e mail cpi catpumps be www catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax 49 6126 9303 33 _ e mail catpumps t online de www catpumps de PN 993152 Rev A 1517
4. forward position Install the screws to fasten gearbox to bearing cover flange Torque per chart MOUNTING PUMP WITH GEARBOX ONTO ENGINE h Rotate crankshaft of engine until keyway is at top 2 Insert key into keyway and generously apply Loctite 76764 antiseize lubricant to engine shaft 3 Line up keyway of pinion gear and engine shaft and carefully slip gearbox onto engine shaft until flush with engine face Install four hex machined screws Torque per chart NOTE Due to varying engine shaft lengths it may be necessary to install a small spacer on each of the four 4 hex machined screws between gearbox flange and engine face 4 Before starting operation fill gearbox housing to oil gauge dot with 80 90 weight gear lube and fill crankcase of pump to oil gauge dot with CAT PUMPS Special Premium Grade Non detergent Oil FIELD CONVERSION FROM STANDARD PUMP To convert from a standard pump to a gearbox pump remove the existing bearing cover gasket and four combi nation head screws Replace with new gearbox bearing cover flange gasket four lockwashers and new hex socket flat head screws The bearing for the 51 56 58 59 and 60 pumps is a tapered roller bearing with outer race Remove the standard bearing cover from the pump Remove outer race from bearing cover by gently pounding on work surface to unseat Then use a bearing puller tool to pull race from bearing cover Next press outer race into gearbox bearing cove
5. 56 58 59 60 70 4 509 25625 Plug Oil Drain 1 4 19BSP 34 35 45 51 56 58 59 60 70 1 M8x25 510 44428 Gasket Flat Flex Oil Gauge 34 35 45 51 56 58 59 60 70 1 526 12489 Washer Flat M8 34 35 45 51 56 58 59 60 70 4 511 92241 Gauge Bubble Oilw Gasket 34 35 45 51 56 58 59 60 70 1 528 12490 Washer Flat M10 34 35 45 51 56 58 59 60 70 4 512 103685 Gasket Flat Flex Oil Cap 34 35 45 51 56 58 59 60 70 1 529 12503 Lockwasher Split M10 34 35 45 51 56 58 59 60 70 4 513 44374 Cap Oil Filler 34 35 45 51 56 58 59 60 70 1 530 34100 Screw Hex Head 34 35 45 51 56 58 59 60 70 4 514 20129 Washer M20 4 1 3 8 16x1 3 8 515 44679 Seal Oil Bearing Cover Flange 34 35 45 51 56 58 59 60 70 1 531 44455 Key 1 4 x1 4 x2 5 32 34 35 45 51 56 58 59 60 70 516 45744 Gasket Flange 51 58 1 532 34042 Spacer 34 35 45 51 56 58 59 60 70 4 45745 Gasket Flange 34 35 1 45759 Gasket Flange 5 59 60 70 1 46121 Gasket Flange 46 1 Before you begin servicing your pump Please carefully read OPERATOR S MANUAL and separate SERVICE MANUAL for special lubrication disassembly and reassembly information s 10 SERVICING THE GEARBOX DISASSEMBLY Completely drain lube from gearbox housing Remove the four HHC screws which fasten the gearbox to the engine and separate gearbox and pump from engine Remove the fo
6. SI 7 to 245 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1570 RPM 1570 RPM Maximum Engine RPM 3200 RPM 3200 RPM ONO nes eena E e ise 0 708 18 mm Horsepower Electric 4 13 2 HP 13 2 HP Stroken A 0 728 18 5 mm Pump Crankcase Capacity 25 oz 0 75 L Weight erennere 36 8 Ibs 16 7 kg Dimensions with G B 13 9 x 10 75 x 8 19 353 x 273 x 208 mm See Models 56 57 59 60 data sheet for information Model 60G1 60 Pump 8071 G B Model 60G118 60 Pump 8078 G B U S Measure Metric Measure POW re ceed yey tttae 4 5 GPM 17 L M Pressure Range 00080e 100 to 4000 PSI 7 to 275 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1570 RPM 1570 RPM Maximum Engine RPM 3200 RPM 3200 RPM BOLG eea MRE Rr Creer E a ace 0 708 18 mm Horsepower Electric 12 3 HP 12 3 HP Stroken a 0 591 15 mm Pump Crankcase Capacity 25 OZ 0 75 L Weight aniio an 36 8 Ibs 16 7 kg Dimensions with G B 13 9 x 10 75 x 8 19 353 x 273 x 208 mm See Models 56 57 59 60 data sheet for pump information Model 70G1 70 Pump 8071 G B Model 70G118 70 Pump 8078 G B U S Measure Metric Measure POW raa aa 4 5 GPM 17 L M Pressure Range 00080e 100 to 5000 PSI 7 to 345 BAR Inlet Pressure Rang
7. e 000c0ee 100 to 1800 PSI 7 to 125 BAR Inlet Pressure Range Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1760 RPM 1760 RPM Maximum Engine RPM 3600 RPM 3600 RPM BONO ei aa Suara EE 0 708 18 mm x Horsepower Electric 9 9 HP 9 9 HP OOKEAN SY 0 945 24 mm Pump Crankcase Capacity 25 oz 0 75 L Weight isi deren esien 36 8 Ibs 16 7 kg Dimensions with G B 13 9 x 10 75 x 18 9 353 x 273 x 208 mm See Models 56 57 59 60 data sheet for pump information Model 58G1 58 Pump 8051 G B Model 58G118 58 Pump 8058 G B U S Measure Metric Measure POW re detest acted at 5 0 GPM 19 L M Pressure Range 00080e 100 to 2500 PSI 7 to 175 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1570 RPM 1570 RPM Maximum Engine RPM 3200 RPM 3200 RPM BONO erea ee E toss 0 708 18 mm x Horsepower Electric 8 6 HP 8 6 HP Stroke eirp n ann a 0 669 17 mm Pump Crankcase Capacity 25 Oz 0 75 L Weight sannin 30 7 Ibs 13 9 kg Dimensions with B 0 13 58 x 10 75 x 8 19 345 x 273 x 208 mm See Models 53 58 55 51 data sheet for pump information Model 59G11 59 Pump 8071 G B Model 59G118 59 Pump 8078 G B U S Measure Metric Measure POW rna aen iaa 5 5 GPM 21 L M Pressure Range cc00008 100 to 3500 P
8. e between bearing cover flange and pump crankcase e Evidence of water in pump crankcase e Evidence of water in gearbox crankcase NOTE If removal of bearing cover flange is necessary completely drain oil from crankcase of pump REMOVING BEARING COVER FLANGE Remove the HSH screws lockwashers and washers from bearing cover flange Tap flange with soft mallet to separate from pump crankcase Examine pump bearing and replace if worn Examine oil seal in bearing cover flange and replace if worn Examine gasket on outside of bearing cover flange and replace if cut or cracked ooh ss 13 Examine o ring on inside outer groove of bearing cover flange and replace if cut or worn lf further pump servicing is needed refer to your pump service manual and Tech Bulletin 035 on Servicing Crankcase Section REPLACING BEARING COVER FLANGE Line up the four holes and mount gasket on outside of bearing cover flange Note Models 56 59 60 and 70 have dual bearings and eight screws Press new seal into bearing cover flange after exercising caution not to cut seal on keyway edge Line up the inside mounting holes on bearing cover flange with the holes on the pump Keep the two outer flanged mounting holes to the top rear and lower front Apply Loctite 242 to the threaded area of screws before replacing Torque per chart REASSEMBLY Insert key into pump crankshaft keyway until flush
9. e oe 4 0 GPM 15 L M Pressure Range 00c0ee 100 to 2000 PSI 7 to 140 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1725 RPM 1725 RPM Maximum Engine RPM 3515 RPM 3515 RPM BONG soi Sutra oaeanneeees 0 787 20 mm x Horsepower Electric 5 5 HP 5 5 HP SOKE aiias re Aea ESY 0 394 10 mm Pump Crankcase Capacity 18 oz 0 55 L Weight ori derenn eeng 24 3 Ibs 11 0 kg Dimensions with G B 11 5 x 10 98 x 8 19 292 x 279 x 208 mm See Models 30 31 34 35 data sheet for pump information Model 35G1 35 Pump 8061 G B Model 35G118 35 Pump 8068 G B U S Measure Metric Measure FOW a ee A aaee 5 0 GPM 19 L M Pressure Range c0000 100 to 1500 PSI 7 to 105 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1725 RPM 1725 RPM Maximum Engine RPM 3515 RPM 3515 RPM BOE sik cae cera edes 0 787 20 mm Horsepower Electric 5 1 HP 5 1 HP SMOKE tren pen SNES 0 472 12 mm Pump Crankcase Capacity 18 oz 0 55 L Weight esssessseesseesererrrrrreenn 24 3 Ibs 11 0 kg Dimensions with G B 11 5 x 10 98 x 8 19 292 x 279 x 208 mm See Models 30 31 34 35 data sheet for pump information Model 45G1 45 Pump 8065 G B U S Measure Metric Measure FOW ie onre he a tutte 4 5 GPM 17 L M Pr
10. essure Range 000008 100 to 3500 PSI 7 to 245 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1645 RPM 1645 RPM Maximum Engine RPM 3353 RPM 3353 RPM BOEan asd oeenn AA Ae Nn 0 630 16 mm xHorsepower Electric 10 8 HP 10 8 HP Stroke sua en n dS iey 0 708 18 mm Pump Crankcase Capacity 18 oz 0 55 L We igitbices sescias iu ate 25 3 Ibs 11 5 kg Dimensions with G B 12 0 x 10 98 x 5 5 345 x 279 139 mm See Model 45 data sheet for pump information Model 51G1 51 Pump 8051 G B Model 51G118 51 Pump 8058 G B U S Measure Metric Measure POW setae eet castle ane S 4 8 GPM 18 L M Pressure Range ccc000e 100 to 3000 PSI 7 to 210 BAR Inlet Pressure Rang Flooded to 60 PSI Flooded to 4 BAR Maximum Pump RPM 1765 RPM 1765 RPM Maximum Engine RPM 3600 RPM 3600 RPM BORO ce ceee setts usa vested 0 630 16 mm x Horsepower Electric 9 8 HP 9 8 HP Strok ahaa re iE 0 728 18 5 mm Pump Crankcase Capacity 25 OZ 0 75 L Weight aeran a 30 7 Ibs 13 9 kg Dimensions with G B 13 58 x 10 75 x 8 19 345 x 273 x 208 mm See Models 53 58 55 51 data sheet for pump information Model 56G1 56 Pump 8071 G B Model 56G118 56 Pump 8078 G B U S Measure Metric Measure POWs Aes geoere a 8 0 GPM 30 L M Pressure Rang
11. r flange Be certain race is completely seated in flange before mounting onto pump TORQUE CHART Description Thread Tool Torque Gearbox Housing to M8 13 mm 70 in Ibs Bearing Cover Flange 8 Nm Bearing Cover Flange to M6 4mm 70 in Ibs Pump M6 8 Nm 125 in Ibs 15 Nm 110 in Ibs 12 Nm Engine Mounting 14mm 110 in Ibs Screw 12 Nm Bearing Cover Flange to 5mm Pump M8 Drive Gear 13 mm Retaining Screw P a 2505 PTS 2485 lO 2 DIMENSIONAL 5 625 010 142 9 optional 1 0 25 4 1 13 28 6 6 42 163 Slot 10 5 x 21 6 Models 34G1 34G118 35G1 35G118 45G1 a u p 4 53 115 20 5 DIMENSIONAL E AAO Hot Sy 6 3 N ey S 6 500 010 165 1 Models 51G1 51G118 56G1 56G118 58G1 58G118 59G1 59G118 ie 60G1 60G118 me 70G1 70G118 World Headquarters CAT PUMPS 1681 94th Lane N E Minneapolis MN 55449 4324 Phone 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpumps com International Inquiries FAX 763 785 4329 e mail intlsales catpumps com L The Pumps with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lane Church Crookham Fleet Hampshire GU52 8BF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A 2550 Kontich Belgium Phone 32 3 450
12. ur HHC screws which fasten the gearbox to the bearing cover flange and separate gearbox hous ing from pump Place gearbox housing on work surface with seal facing up Remove pinion oil seal by inserting screwdriver between pinion gear and inner lip of seal and pry out Seal will be damaged and must be replaced Remove large retaining ring in groove below the pinion oil seal using retaining ring pliers and set aside for re use Remove the pinion gear and bearing Turn gearbox housing over onto engine mount flange surface Bearing is pressed into position so it is necessary to press pinion and bearing out from rear Set gearbox housing aside Remove bearing from pinion gear Using reverse pliers remove retaining ring from groove on pinion gear and press bearing from pinion Set aside pinion bearing and retaining ring Remove hex machined retaining screw lockwasher and flat holding washer from center of helical drive gear on pump shaft Slip helical drive gear from crankshaft Remove key from keyway in pump crankshaft At this point the gearbox has been disassembled Now begin examination of the gearbox parts for wear and reassembly While the gearbox is in this state of disassembly it is advisable to examine your pump for any indication of drive end wear If any of the following conditions are present removal of the bearing cover flange is necessary Only trained technicians should service drive end e Leakag
13. washer Conical M8 4 4 8071 Gearbox Helical 1 Shaft 56 59 60 70 1 519 45763 Screw Hex Socket 34 35 51 56 58 59 60 70 4 8 8078 Gearbox Helical 1 1 8 Shaft 56 59 60 70 1 Flat Head M6x16 502 44673 Housing 34 35 45 51 58 1 46124 Screw Hex Socket 465 4 45351 Housing 56 59 60 70 1 Flat Head M8x16 503 44675 Gear Pinion 1 34 35 45 51 58 1 520 14045 O Ring Flange 34 35 45 51 56 58 59 60 70 1 45352 Gear Pinion 1 56 59 60 70 1 521 44680 Gear Helical Drive 51 56 58 59 60 70 1 44690 Gear Pinion 1 1 8 34 35 51 58 1 44711 Gear Helical Drive 34 35 45 1 45358 Gear Pinion 1 1 8 56 59 60 70 1 522 44459 Key M8x7x24 51 56 58 59 60 70 1 504 56110 Bearing Ball 34 35 45 51 56 58 59 60 70 1 2 101814 Key M6x6x27 34 35 45 1 505 55459 Retainer Ring External 34 35 45 51 56 58 59 60 70 1 523 26118 Washer Flat Holding 34 35 45 51 56 58 59 60 70 1 506 146423 Retainer Ring Internal 34 35 45 51 56 58 59 60 70 1 524 92521 Screw Sems Hex Head 34 35 45 51 56 58 59 60 70 1 507 44676 Seal Oil Case Pinion 34 35 45 51 56 58 59 60 70 1 Retaining M8x20 508 23170 O Ring Drain Plug 34 35 45 51 56 58 59 60 70 1 525 92530 Screw Sems Hex Head 34 35 45 51
14. with end of shaft Examine helical drive gear teeth for wear and replace if necessary Line up keyway on gear with pump shaft key way and key and slide onto shaft Install flat holding washer lockwasher and retaining screw onto shaft and torque per chart Examine gearbox oil gauge and oil drain plug for any evidence of leaking and replace o ring and gasket if necessary Examine pinion bearing for wear and replace if necessary Examine pinion gear teeth for wear and replace if necessary Press bearing over pinion gear until seated on shoulder Models with dual bearings press first bearing on until seated then second bearing until seated up to first bearing Install retaining ring on pinion gear and snap into groove Insert pinion and gear assembly into gearbox housing and press into position until seated on shoulder Groove for large retaining ring must be visible Insert large retaining ring into pinion bearing housing and snap into groove Lubricate I D and O D of new pinion oil seal Place oil seal at mouth of pinion bearing housing with garter spring facing down Carefully press seal into position until seated on retaining ring Keep seal square in posi tion to avoid inner lip hanging up on pinion gear edge Rotate pinion gear so keyway is up Mount assembled gearbox housing onto pump shaft with helical drive gear NOTE Carefully match gear teeth and line up mounting holes Place engine mounting flange in
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