Caterpillar Cat 5090B FRONT SHOVEL (Prefix CLD) Service Repair Manual (CLD00001 and up)

1
Service Repair Manual
Models 5090B FRONT SHOVEL
2
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Product FRONT SHOVEL Model 5090B FRONT SHOVEL
CLD Configuration 5090B Excavator CLD00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 385B and 5090B
Excavators Excavator Systems Media Number
-RENR5407-06 Publication Date -01/02/2016
Date Updated -12/02/2016
i02011964
Swing Drive - Assemble SMCS - 5459-016 Assembly
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-5197 Pliers 1
B 138-7574 Link Brackets 2
C 138-7575 Link Bracket 3
Note Cleanliness is an important factor. Before
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry.
Wiping cloths or rags should not be used to dry
parts. Lint may be deposited on the parts which
may cause later trouble. Inspect all parts. If
any parts are worn or damaged, use new parts for
replacement.
3
Illustration 1 g00869899 1. Install lip type
seals (32) and O-ring seal (33) in bearing cage
(29).
Illustration 2 g00870134 Note Lubricate the
seals and the seal surface of the shaft before
you install the cage assembly. 2. Carefully
install cage (29) on shaft (31).

• Illustration 3 g00870142
• Raise the temperature of bearing (36) to 135 C
  (275 F) and use two people to install the
  bearing on shaft (31). The weight of bearing (36)
  is approximately 35 kg (77 lb).
• Install spacer (35) on shaft assembly (31).
  Install the spacer with relief against bearing
  (36).

4
Illustration 4 g00870160 5. Raise the
temperature of bearing (34) to 135 C (275 F).
Install the bearing on shaft (31) and against
spacer (35).
Illustration 5 g00870169 6. Use Tooling (A ) to
install retaining ring (28) on shaft (31) and
against bearing (34).
Illustration 6 g01040433 7. Install shaft
assembly (31) in swing drive housing (16).
5

1. Apply 5P-3931 Anti-Seize Compound on the inside
   diameter of swing drive housing (16).
2. Lower the temperature of shaft assembly (31).
3. Attach Tooling (C) and a suitable lifting device
   to shaft assembly (31).
4. Install the shaft assembly into swing drive
   housing (16). Bearing (34) must be within the
   bore of the swing drive housing.
5. Remove Tooling (C) and the lifting device from
   shaft assembly (31). Attach the tooling and the
   lifting device to the swing drive housing.
6. Lift the swing drive vertically. Use a hammer and
   a drift to align bearing (34) in the lower bore
   of the swing drive housing. When the bearing is
   properly aligned in the bore, shaft assembly (31)
   will drop into the proper position within the
   swing drive housing.

• Illustration 7 g00870264
• Apply 1U-8846 Sealant on the threads of bolts
  (30).
• Install bolts (30) and washers in bearing cage
  (29) and swing drive housing (16).

Illustration 8
g00869483
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• Illustration 9 g00870281
• Install bearings (24) and (26) in gear (25).
• Install gear (25) and washers (23) and (27) in
  carrier (20).
• Lower the temperature of shaft (22). Install the
  shaft in carrier assembly (20).
• Install pin (21) in the carrier assembly and the
  shaft.
• Use a hammer and a center punch to stake the pin
  in the carrier housing.
• Repeat Steps 10 through Steps 14 on the three
  remaining gear assemblies.

Illustration 10 g00869464 16. Use a suitable
lifting sling to install carrier assembly (20).
The weight of carrier assembly (20) is
approximately 68 kg (150 lb).
8
Illustration 11
g00869460
17. Install retaining ring (19).
Illustration 12 g00869406 18. Install spacer
(17) in carrier assembly (18).
Illustration 13 g00869390 19. Make sure that the
mating surfaces of ring gear (15) and swing drive
housing (16) are thoroughly clean.
9

• Apply 1U-8846 Gasket Sealant to the face of swing
  drive housing (16) and the face of ring gear
  (15).
• Use Tooling (B) and a suitable lifting device to
  install ring gear (15) in swing drive housing
• (16). The weight of ring gear (15) is
  approximately 80 kg (175 lb).

Illustration 14 g00869383 22. Install retaining
ring (14) into the sun gear.

• Illustration 15 g00869377
• Install sun gear (13) in carrier assembly (4).
  Install upper retaining ring (12).
• Assemble carrier assembly (4).

10

• Illustration 16 g00869315
• Apply clean SAE 30W oil on bearing (10). Install
  bearing (10) in planetary gear (9).
• Install thrust washer (8) on one side of
  planetary gear (9).
• Install thrust washer (11) on the other side of
  planetary gear (9).
• Use a deburring tool to remove the metal burr
  from the openings in the carrier.
• Install planetary gear (9) and the thrust washers
  in carrier assembly (4).

Illustration 17 g00869309 f. Install planetary
shaft (7) through the gear assembly into the
carrier assembly. Make sure that the spring pin
hole in the planetary shaft is in alignment with
the spring pin hole in the carrier.
Illustration 18
g00703700
11

1. Drive spring pin (6) into shaft (7). Orient the
   split in spring pin (6) vertically to the
   carrier. Align the split in the spring pin to the
   top or the bottom. Make a stake mark on each side
   of the spring pin hole in the carrier. Each stake
   mark should be approximately 2.25 0.75 mm (0.09
   0.03 inch) from the outside diameter of the
   spring pin hole.
2. Repeat Steps 24.a through 24.g in order to
   install the other three planetary gears in the
   carrier.

• Illustration 19 g00869294
• Use two people to install carrier assembly (4) in
  the ring gear. The weight of carrier assembly (4)
  is approximately 36 kg (80 lb).
• Install spacer (5) in carrier assembly (4).

Illustration 20 g00869281 27. Install sun gear
(3) in carrier assembly (4).
12

• Illustration 21 g00869266
• Make sure that the mating surfaces of the ring
  gear and cover (2) are thoroughly clean.
• Apply 1U-8846 Gasket Sealant on the flange
  surface of the ring gear and cover (5).
• Install cover (2) and bolts (1).
• End By
• a. Install the swing drive. Refer to Disassembly
  and Assembly, "Swing Drive - Remove and Install".

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Mon Jan 25 104354 UTC0800 2021
13
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Product FRONT SHOVEL Model 5090B FRONT SHOVEL
CLD Configuration 5090B Excavator CLD00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 385B and 5090B
Excavators Excavator Systems Media Number
-RENR5407-06 Publication Date -01/02/2016
Date Updated -12/02/2016
i01643559
Swing Drive - Install SMCS - 5459-012 Installatio
n Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
(A) 132-8223 110 V Power Pack 1
(A) 1U-6221 Torque Wrench 1
(A) 132-8143 Hex Link 1
(B) 138-7574 Link Bracket 2

• Thoroughly clean the mating surfaces of the swing
  drive housing and the main frame.
• Apply 5P-3931 Anti-Seize Compound on the locating
  pin in the swing drive housing. Apply
• 5P-3931 Anti-Seize Compound in the pin bore in
  the main frame.
• Apply 1U-8846 Liquid Gasket on the mating
  surfaces of the main frame and the swing drive.
• Note During installation, the locating pin for
  the swing drive can come out of the swing drive
  housing.

14
Illustration 1 g00849051 4. Fasten Tooling (B)
and a suitable lifting device to swing drive (2).
The weight of the swing drive is approximately
503 kg (1110 lb). Put the swing drive in the
drive's original position in the main frame. If
the locating pin comes out of the swing drive
housing, the locating pin can be reinstalled with
a hammer after the swing drive is in place.

• Illustration 2 g00849041
• Apply 9S-3263 Thread Lock Compound on the threads
  of bolts (1). Install the washers and bolts (1)
  that hold the swing drive in place. Use Tooling
  (A) to tighten the bolts to a torque of 900 100
  Nm (665 75 lb ft).
• Install the two corks in the threaded holes in
  the swing drive housing.
• After the installation of the swing motor, fill
  the swing drive with hydraulic oil to the correct
  level. The capacity of the swing drive is 19 L (5
  US gal). Refer to Operation and Maintenance
  Manual for the correct filling procedure.
• End By
• a. Install the swing motor. Refer to Disassembly
  and Assembly, "Swing Motor - Install" in this
  manual.

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Mon Jan 25 104451 UTC0800 2021
15
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Product FRONT SHOVEL Model 5090B FRONT SHOVEL
CLD Configuration 5090B Excavator CLD00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 385B and 5090B
Excavators Excavator Systems Media Number
-RENR5407-06 Publication Date -01/02/2016
Date Updated -12/02/2016
i01640364
Swing Pump - Remove SMCS - 5473-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
Start By a. Remove the fan pump. Refer to
Disassembly and Assembly, "Fan Pump -
Remove". 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 Dealer Service Tool
Catalog" for tools and supplies suitable to
collect and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.
16
At operating temperature, the hydraulic oil is
hot and under pressure. Hot oils can cause
burns. To prevent possible personal injury,
release the pressure in the work tool hydraulic
circuit (boom, stick, bucket, and swing), travel
circuits, and the hydraulic oil tank at the
filler cap before any hydraulic lines or
components are disconnected or removed. Remove
the filler cap only when the engine is stopped
and the filler cap is cool enough to touch.
1. Drain the hydraulic oil. The capacity of the
hydraulic system is 996 L (263 US gal).
Illustration 1 g00847704 2. Open the door on the
right side of the machine.
Illustration 2 g00847839 3. Remove bolts (2) and
remove hood (1). Release rubber latches (4) and
open cover (3).
17
Illustration 3 g00847852 4. Cut cable straps (5)
and disconnect wiring harness (6).
Illustration 4 g00847856 5. Remove bolts (7) and
(8). Position filters (9) and (10) out of the way.
Illustration 5
g00847859
6. Remove bolts (11).
18
Illustration 6
g00847866
7. Remove bolts (12).
Illustration 7
g00847877
8. Remove bolts (13).
Illustration 8 g00847882 9. Remove bolts (14).
Loosen clamps (15) and slide hose (16) rearward.
19
Illustration 9 g00847887 10. Install Tooling
(A). Use Tooling (A) and a hoist to remove the
cover and support assembly (17). The weight of
cover and support assembly (17) is approximately
148 kg (325 lb).
Illustration 10 g00848368 11. Disconnect hose
assemblies (18) and (20). Disconnect wiring
harness (19).
Illustration 11 g00848390 12. Support pump
assembly (21) with a lifting sling and a hoist.
Remove hose assemblies (22) and (23). Remove
coupling (25). Remove bolts (24) and pump (21).
The weight of the pump is approximately 152 kg
(335 lb).
20
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Previous Screen
Product FRONT SHOVEL Model 5090B FRONT SHOVEL
CLD Configuration 5090B Excavator CLD00001-UP
(MACHINE) POWERED BY 3456 Engine
Disassembly and Assembly 385B and 5090B
Excavators Excavator Systems Media Number
-RENR5407-06 Publication Date -01/02/2016
Date Updated -12/02/2016
i01636512
Swing Pump - Disassemble SMCS -
5473-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
(A) 138-7575 Link Bracket 2
(B) 1P-0510 Driver Group 1
(C) Forcing Screws 2
(D) 1P-1864 Retaining Ring Pliers 1
Start By a. Remove the swing pump. Refer to
Disassembly and Assembly, "Swing Pump and Pump
Drive - Remove" in this manual. Note Regular
maintenance and frequent inspections are routine
precautions. Practice preventive maintenance
before damage occurs. Preventive maintenance can
help to avoid a failure. If a failure occurs, an
accurate diagnosis of the cause can prevent a
recurrence. Information is available to analyze
failures for piston pumps and motors. Refer to
Special Publication, SEBD0641, "Analyzing Axial
Piston Pump and Motor Failures". Note Many
times, the installation of new parts is not
necessary. The installation of used parts during
reconditioning is acceptable. Used parts can
result in a substantial cost reduction. Reusable
information is available on piston pumps and
motors. Refer to Special Publication, SEBF8032,
"Guideline For Reusable Parts - Piston Pumps and
Motors". During reconditioning, correct any
conditions that might have caused the original
failure.
21
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. Dirt and contaminants can damage
precision components that are in pumps and
motors. All disassembly and assembly procedures
must be performed on a clean work surface. Clean
all the interior components in clean solvent. Dry
all the interior components with compressed air.
Plug ports and plug hoses on the machine during
repair. 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 Dealer Service Tool
Catalog" for tools and supplies suitable to
collect and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.
Note The hydraulic oil must be contained in the
proper manner. Refer to Special Publication,
NENG7004, "Contamination Control Catalog". Note
The weight of the swing pump is approximately 152
kg (335 lb).
Illustration 1 g00602845 1. Remove coupling (1)
from pump assembly (2).
22
Illustration 2 g00602846 2. Remove screws (3)
and actuator (4) from head assembly (5) and pump
assembly (2).
Illustration 3
g00602848
3. Remove rod (6) from head assembly (5).
Illustration 4 g00602857 4. Remove bolts (7)
from head assembly (5) and pump assembly (2).
23

• Illustration 5 g00602861
• Attach Tooling (A) and a suitable lifting device
  to head assembly (5).
• Note The port plate can fall when the head
  assembly is removed.
• Carefully remove head assembly (5) from pump
  assembly (2).

Illustration 6 g00602866 7. Remove port plate
(8) from head assembly (5).
Illustration 7 g00602895 8. Remove O-ring seals
(9) and spring (10) from actuator (4).
24
Illustration 8 g00602898 9. Remove seal (11)
from the adjuster on actuator (4).
Illustration 9
g00602905
10. Remove adjuster (12) from actuator (4).
Illustration 10
g00848296
11. Remove solenoid (13) from actuator (4).
25
Illustration 11 g00602953 12. Remove spool
assembly (14) from actuator (4).
Illustration 12 g00602994 13. Remove retainer
(15) and O-ring seal (16). Remove stem (17) and
O-ring seal (18) from spool (14).
Illustration 13 g00602995 14. Remove seat (19)
and spring (20) from stem (17).
26
Illustration 14
g00602997
15. Remove sensor (21) from actuator (4).
Illustration 15 g00602998 16. Remove O-ring seal
(22) from solenoid (13).
Illustration 16 g00848138 17. Remove the bolts
and adapter plate (23) from head assembly (5).
27
Illustration 17 g00847666 18. Remove O-ring seal
(24) and O-ring seal (25) from adapter plate (23).
Illustration 18 g00848139 19. Remove the bolts
and adapter (26) from head assembly (5).
Illustration 19 g00848140 20. Remove O-ring seal
(27) from adapter (26).
28
Illustration 20
g00848141

• Illustration 21 g00848145
• If necessary, remove pins (28) and test port (30)
  from head assembly (5).
• Use Tooling (B) to remove bearing (29) from head
  assembly (5).

Illustration 22 g00604211 Note Port plate (8 )
can be removed with the head assembly. 23. Remove
port plate (8). Remove piston assemblies (31) and
(32). Remove O-ring seal (33).
29
Illustration 23 g00604046 24. Disassemble piston
assembly, as follows rod (34), piston (35) and
spring (36).
Illustration 24 g00604213 25. Disassemble piston
assembly, as follows rod (37), piston (38) and
spring (39).
Illustration 25 g00604215 26. Remove bolts (40).
Use caution when the bolts are removed. The bolts
are installed with thread lock. Remove retainers
(41).
30
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Illustration 26 g00604218 27. Measure the length
of pins (42) for installation purposes. Loosen
locknuts (43). Tighten the pins in order to
contact the swashplate. Tighten the locknuts.
Illustration 27 g00604220 28. Place the pump on
a level surface. Remove barrel assembly (44).
Keep the barrel assembly together with the
pistons.
Illustration 28 g00604224 29. Mark the pistons
so the pistons can be installed in the original
bores.
32

1. Remove pistons (45) from barrel (47) and plate
   (46) for the pistons.
2. Remove plate (46).

Illustration 29
g00604226
32. Remove spring retainer (48).
Illustration 30
g00604228
33. Remove springs (49).
Illustration 31
g00604231
33
34. Remove shims (50).
Illustration 32
g00604218
Illustration 33 g00604233 35. Loosen locknuts
(43). Remove pins (42). Remove swashplate
assembly (51).
Illustration 34 g00604235 36. Remove bearings
(53) from swashplate (52). Remove pins (54).
34
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