Denison Hydraulics Goldcup Series Operating and installation instructions

Axial Piston Motors Series
Fixed Displacement M24 Design D
Goldcup M30 Design A
Service Information
S2-AM121 12-94 replaces SFM-M24
CONTENTS
PAGE
INTRODUCTION 2
GENERAL 2
DESCRIPTION 2
TABLE I CHARACTERISTICS 2
INSTALLATION 3-4
MOUNTING 3
SHAFT INFORMATION 3
PIPING 3
SERVICE INFORMATION 3
RECOMMENDED FLUIDS 3
VISCOSITY 3
VISCOSITY INDEX 3
TEMPERATURE 3
ALTERNATE FLUIDS 4
MAINTENANCE 4
FLUID CLEANLINESS 4
START UP PROCEDURE 4
TABLE II SOLID CONTAMINATION 4
TABLE III TROUBLE-SHOOTING 5-6
UNIT DISASSEMBLY 7-8
TABLE IV REWORK LIMITS 8
DISASSEMBLY & ASSEMBLY TOOL DRAWING 8
PAGE
ASSEMBLY PROCEDURES 9-20
FIGURE 1 DRIVE SHAFT ASSEMBLY 9
FIGURE 2 BARREL, CAM, PISTON @ SHOE
ASSEMBLY TO MOUNTING FLANGE 11
FIGURE 3 BARREL AND AUXILIARY
SHAFT ASSEMBLY (24 SERIES) 12
FIGURE 3.1 BARREL AND AUXILIARY
SHAFT ASSEMBLY (30 SERIES) 13
FIGURE 4 HOUSING ASSEMBLY 14
FIGURE 5
HOUSING ASSEMBLY INSTALLATION 15
FIGURE 6 SHAFT SEAL AND COVER ASSEMBLY 16
FIGURE 7 PORT BLOCK INSTALLATION 18
FIGURE 8
SHUTTLE VALVE ASSEMBLY 20
TEST PROCEDURES 21
GENERAL REQUIREMENTS 21
BASIC MOTOR TEST 21
ORDERING CODE 22
SEAL KIT
COMPLETE S23-15128
SHAFT SEAL KITS S23-11516
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Introduction Series 24, 30
General
This manual contains installation, operation, maintenance
and overhaul instructions for Denison Hydraulics Goldcup
24 and Goldcup 30 constant volume motors. The Denison
Hydraulics Goldcup 24 and Goldcup 30 axial piston motors
feature advance design concepts which are time proven
and provide for advance pumping and control concepts.
The instructions contained in this manual cover complete
disassembly and reassembly of the unit. Before proceed-
ing with the disassembly or reassembly of any unit, this
manual should be studied in order to become familiar with
proper order and parts nomenclature.
Description
The Goldcup motor is a fixed displacement, axial piston
design which uses hydrostatically balanced piston shoes.
This feature serves to lubricate as well as absorb much
of the force generated by the shoes pressing against the
cam, thereby increasing service life of the unit. Rotation
of the unit is bi-directional.
2
TABLE I TYPICAL CHARACTERISTICS
Specification Term Goldcup 24 Goldcup 30
Displacement in.3/rev 24.6 30.6
cm3/rev (403) (501.4)
Pressure Ports A & B max. continuous psi 5000 5000
bar (345) (345)
max. intermittent psi 5000 5000
bar (345) (345)
Speed, max. continuous @ full stroke RPM 2100* 1800
Flow, Ports A or B GPM @ 2100 RPM 223.6 @ 1800 RPM 238
(theoretical) L/min. (846) (901)
Rotary Inertia lb/in2818 974
kg/m2(0.239) (0.285)
Torque, Theoretical in/lb 392 487
per 100 PSI (6.9 bar) N•m (43) (55)
at 5000 PSI (345 bar) in/lb 19576 24351
N•m (2158) (2752)
Power, Theoretical @ 5000 PSI (345 bar) hp 31.1 38.64
at 100 RPM kW (23.1) (28.8)
Power, Theoretical at 5000 PSI (345 bar) hp 621.3 695**
at Max. RPM kW (463.5) (518)**
Torque Efficiency approx. stalled % theoretical 81 81
running % theoretical 93 93
Mounting-4 bolt flange SAE F F
Shaft-Spline / Keyed SAE F F
Fluid Connection Ports A & B in 2 2
SAE-4 bolt pad for 6000 psi split flange mm (50.8) (50.8)
(414 bar)
Weight lbs. 640 660
kg. (290) (300)
*On R & O Oils (Rust and Oxidation Inhibitor)
** @ 1800 RPM
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3
Installation Series 24, 30
Mounting
This motor is designed to operate in any position. The
mounting hub and four bolt mounting flange are in full con-
formance with SAE standard. The motor shaft must be in
alignment with the shaft of the driven load and should be
checked with a dial indicator. The mounting pad or adap -
tor into which the fluid motor pilots must be concentric with
the motor shaft to prevent bearing failure. This concentric-
ity is particularly important if the shaft is rigidly connected
to the driven load without a flexible coupling.
Shaft Information
Splined: The shafts will accept a maximum misalignment
of 0.006" TIR (.15 mm). Angular misalignment at the male
and female spline axes must be less than ±.002 (0.05
mm) per one inch radius. The coupling interface must be
lubricated. Denison Hydraulics recommends lithium
molydisulfate or similar grease. The female coupling
should be hardened to 45-50 Rc and must conform to
SAE-J498B (1971) Class 1 flat root side fit.
Keyed: High strength heat treated keys must be used.
Replacement keys must be hardened to 27-34 Rc. The key
corners must be chamfered .030"-.040" (.75-1 mm) at 45°
to clear radii that exist in the keyway.
Keyed types of shafts will accept a side load of 1000 lbs.
(454 kg) at the center of the key, with a B10 life of 9,880
hours at 1800 RPM or 11,856 hours at 1500 RPM.
Piping
Connect inlet and outlet lines to the port block of the motor.
The fluid connections are:
System Ports: 2" (50.8 mm)
6000 PSI (414 bar), SAE
4 bolt flange
Other: SAE straight thread, O-ring seal.
See installation drawing for sizes.
The maximum case pressure is 75 PSI (5.17 bar) contin-
uous,125 PSI (8.6 bar) intermittent.
It is recommended that the case leakage line be connect-
ed to the port located between the two system ports on the
port block, but it may be connected to the top or bottom
connections on the motor housing.
The case leakage line must be of sufficient size to prevent
back pressure in excess of 75 PSI (5.7 bar) and returned
to the reservoir below the surface of the oil as far from the
supply suction as possible. All fluid lines, whether pipe, tub-
ing, or hose must be adequate size to assure free flow
through the motor. We recommend 20 ft (6.09 M) max. per
second for main flow and 6 ft. (1.8 M) max. limit per sec-
ond for drain lines. Pressure rating of piping hose must be
adequate for service duty required.
An undersized outline line will create back pressure and
cause improper operation. Flexible hose lines are recom-
mended. If rigid piping is used, the workmanship must be
accurate to eliminate strain on the port block or to the fluid
connections. Sharp bends in the lines must be eliminated
wherever possible. All system piping must be cleaned with
solvent or equivalent before installing motor. Make sure the
entire hydraulic system is free of dirt, lint, scale, or other
foreign material. Flushing with a large temporary high pres-
sure loop filter is recommended.
Service Information
These hydraulic products are designed to give long
dependable service when properly applied and their sys -
tems properly maintained. These general instructions apply
to typical systems. Specific instructions for particular equip-
ment can be developed from them.
Recommended Fluids
The fluid recommended for use in these pumps and motors
has a petroleum base and contains agents which provide
oxidation inhibition and anti-rust, anti-foam and de-aerat -
ing properties as described in Denison Hydraulics standard
HF-1. Where anti-wear additive fluids are specified, see
Denison Hydraulics standard HF-0.
Viscosity:
Max. at cold start—7500 SUS (1600 Cst)
(at low pressure, low speed)
Max. at full power—750 SUS (160 Cst)
Optimum for max. life—140 SUS (30 Cst)
Minimum at full power—60 SUS (10 Cst)
Viscosity Index:
90 V.I. minimum. Higher values extend the range of oper-
ating temperature but may reduce the service life of the
fluid.
Temperature
Determined by the viscosity characteristics of the fluid
used. Because high temperatures degrade seals, reduce
the service life of the fluid and create hazards, fluid tem -
peratures should not exceed 180 °F (82°C) at the case
drain.
CAUTION: Do not use galvanized pipe. Galvanized
coating can flake off with continued use.
NOTE: High case pressure will result in reduced B-
10 life of the shaft bearing.
NOTE: Do not impact coupling to force it onto the
shaft.
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Installation Continued Series 24, 30
Alternate Fluids
Some applications require fire-resistant fluids. They will
give good service if the system is originally designed for
their use. Permissible fire resistant fluids include:
Type Denison Hydraulics Standard
Water-in-oil invert emulsions HF-3
Water glycol solutions HF-4
Phosphate esters HF-5
Consult Denison Hydraulics for design requirements and
warranty limitations for service with this class of fluids.
See Denison Hydraulics bulletin SPO-AM305 for more infor-
mation.
Maintenance
This motor is self-lubricating and preventative maintenance
is limited to keeping system fluid clean by changing filters
frequently. Keep all fittings and screws tight. Do not oper-
ate at pressures and speeds in excess of the recommended
limit. If the motor does not operate properly, check the
Trouble Shooting Chart before attempting to overhaul the
unit. Overhauling is relatively simple and may be accom -
plished by referring to the Disassembly, Rework Limits of
Wear Parts and Assembly Procedures.
Fluid Cleanliness
Fluid must be cleaned before and continuously during oper-
ation by filters that maintain a cleanliness level of NAS1638
Class 8. This approximately corresponds to ISO 17/14.
This fluid level cleanliness can usually be accomplished by
the effective use of 10 micron filters. Better cleanliness lev-
els will significantly extend the life of the components. As
contaminant generation may vary with each application,
each must be analyzed to determine proper filtration to
maintain the required cleanliness level.
Start Up Procedure for New Installation
1. Read and understand the instruction manual. Identify
components and their functions.
2. Check alignment of drive.
3. Visually inspect components and lines for possible
damage.
4. Check reservoir for cleanliness and clean as required.
White glove test on all internal surfaces is recommended.
5. Check fluid level and fill as required with filtered fluid at
least as clean as that recommended. Fill motor case with
clean oil prior to starting.
6. Check oil cooler and activate it, if included in circuit.
Check fluid temperature.
7. Reduce pressure settings of pressure control. Make
sure accurate pressure readings can be made at appro -
priate places.
8. If solenoids in system, check for actuation.
9. Start pump drive first by jogging prime mover. Make sure
pump and motor fill properly.
10. Bleed system of air. Recheck fluid level.
11. Cycle unloaded machine at low pressure and observe
actuation (at low speed, if possible).
12. Increase pressure settings gradually in steps. Check
for leaks in all lines especially in pump and motor inlet lines.
13. Make correct pressure adjustments.
14. Gradually increase speed. Be alert for trouble as indi-
cated by changes in sounds, system shocks and air in fluid.
Inspect oil surface with a good light while in operation. There
must be no surface broken with oil surges and limit surface
air bubbles to occasional.
15. Equipment is operational.
4
TABLE II
COMPARISON OF SOLID CONTAMINATION CLASSIFICATION SYSTEMS
NATIONAL AEROSPACE STANDARD (NAS) 1638
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5
Table III Trouble-shooting Chart Series 24, 30
Trouble-Shooting
Component problems and circuit problems are often inter-
related. An improper circuit may operate with apparent suc-
cess but will cause failure of a particular component with-
in it. The component failure is the effect, not the cause of
the problem.
This general guide is offered to help in locating and elimi-
nating the cause of problems by studying their effects:
Effect of Trouble Possible Cause Fault Which Needs Remedy
Noisy Motor Air in Fluid Leak in suction line
Leak at shaft seal
Low fluid level
Turbulent fluid
Return lines above fluid level
Gas leak from accumulator
Excessive pressure drop in the inlet line
from a pressurized reservoir
Suction line strainer acting as air trap
Cavitation in motor Fluid too cold
rotating group Fluid too viscous
Fluid too heavy
Shaft speed too high
Suction line too small
Suction line collapsed
Operating altitude too high
Boost or replenishment pressure too low
Replenishment flow too small for
dynamic conditions
Misaligned shaft Faulty installation
Distortion in mounting
Axial interference
Faulty coupling
Excessive overhung loads
Mechanical fault in motor Piston and shoe looseness or failure
Bearing failure
Incorrect port plate selection or index
Erosion on barrel ports and port plate Air in fluid See above
Cavitation See above
High wear in motor Excessive loads Reduce pressure settings
Reduce speeds
Contaminant particles in fluid Improper filter maintenance
Filters too coarse
Introduction of dirty fluid to system
Reservoir openings
Improper reservoir breather
Improper line replacement
Improper fluid Fluid too thin or thick for operating
temperature range
Breakdown of fluid with
time/temperature/shearing effects
Incorrect additives in new fluid
Destruction of additive effectiveness with
chemical aging
Improper repair Incorrect parts
Incorrect procedures, dimensions, finishes
(Continued)
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Table III Continued Series 24, 30
6
Effect of Trouble Possible Cause Fault Which Needs Remedy
High Wear in motor Unwanted water in fluid Condensation
Faulty breather/strainer
Heat exchanger leakage
Faulty clean-up, practice
Water in makeup fluid
Pressure shocks Cogging load Mechanical considerations
Worn relief valve Needed repairs
Worn compensator Needed repairs
Slow response in check valves Replace or relocate
Excessive decompression Improve decompression control
energy rates
Excessive line capacitance Reduce line size or lengths.
(line volume, line stretch, Eliminate hose
accumulator effects)
Barrel blow-off Recheck hold-down, rotating group,
drain pressure
Heating of fluid Excessive motor leakage Recheck case drain flow and repair as
required
Fluid too thin
Improper assembly, port timing
Relief valve Set too low (compared to load or to compen-
sator)
Instability caused by back pressure,
worn parts
Heat exchanger Water turned off or too little flow
Water too hot
Fan clogged or restricted
Efficiency reduced by mud or scale deposits
Intermittent hydraulic fluid flow
Reservoir Too little fluid
Entrained air in fluid
Improper baffles
Insulating air blanket that prevents
heat rejection
Heat pickup from adjacent equipment
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7
Unit Disassembly Series 24, 30
Disassembly
The instructions contained in this section cover a complete
teardown of the subject motor. Disassemble only as far as
necessary to replace or repair any worn parts. A bench or
similar suitable surface capable of supporting unit should
be used. Disassembly area should be clean.
Shuttle Valve Assembly
See Figure 7
1. Remove three screws (13) and remove valve assembly
from port block.
24 Series Barrel Holddown
See Figure 3
1. Remove holddown lock retainer ring (8, Figure 3). (Use
internal snap ring pliers.)
2. Remove four screws (1, Figure 7) and two screws (8,
Figure 7).
3. Carefully lift and remove port block (2) and port plate (4,
Figure 7).
4. Remove the face plate and face plate pins (2, 1, Figure
5) from the face of the barrel assembly.
5. Remove holddown adjusting screw lock (7, Figure 3).
6. Lock main shaft (1, Figure 6) from turning. Use special
tool T2, slip over auxiliary shaft (2, Figure 3) and engage
dowels into holddown adjusting screw (6, Figure 3). Loosen
load but do not remove.
7. Remove two bolts (8, Figure 7) holding housing and
flange together.
8. Barrel assembly can be removed by lifting with aux.
shaft. The pistons will remain with the cam assembly.
These parts are precision finished and must be handled
with extreme care!
9. Using special tool T2, holddown assembly can be
removed from barrel. Remove adjusting screw (6, Figure
3), spring (5), retainer (4), spherical seat (3) and auxiliary
shaft (2).
30 Series Barrel Holddown
See Figure 3.1
1. Remove four screws (1, Figure 7) and two screws
(8, Figure 7).
2. Carefully lift and remove port block (2) and port plate
(4, Figure 7).
3. Remove the face plate and face plate pins (2, 1, Figure
5) from the face of the barrel assembly.
4. Loosen six screws gradually in alternating sequence.
5. Insert three #10-32 screws into the three #10-32 tapped
holes. Alternately turn in screws till tapered retainer releas-
es. A loud crack sound should be heard when it releases.
6. Lock main shaft (1, Figure 6) from turning. Use special
tool T2, slip over auxiliary shaft (2, Figure 3.1) and engage
dowels into holddown adjusting screw retainer (6, Figure
3.1). Loosen load but do not remove.
7. Remove two bolts (8, Figure 7) holding housing and
flange together.
8. Barrel assembly can be removed by lifting with auxiliary
shaft. The pistons will remain with the cam assembly.
These parts are precision finished and must be handled
with extreme care!
NOTE: Do not damage gasket faces in process. Do
not remove the retaining screws or bearing from the
housing unless bearing is damaged and replacement
is necessary.
CAUTION: Holddown is under preload. Do not re -
move screws completely.
CAUTION: The port plate may cling to the barrel
face because of oil film. Do not allow the port plate
to fall and become damaged.
NOTE: There is a preload from the barrel holddown
which will lift the port block approx. 1⁄8" at release.
NOTE: Do not damage gasket faces in process. Do
not remove the retaining screws or bearing from the
housing unless bearing is damaged and replacement
is necessary.
CAUTION: The port plate may cling to the barrel
face because of oil film. Do not allow the port plate
to fall and become damaged.
NOTE: There is a preload from the barrel holddown
which will lift the port block approx. 1⁄8" at release.
NOTE: The four main assembly bolts (1, Figure 9) are
torqued to 450 ft. lbs. (610 N•m) These bolts should
be loosened prior to removing unit for disassembly.
CAUTION: On 24 Series units relax barrel holddown
prior to removal of shaft seal or main shaft. Failure to
follow this procedure may result in motor failure.
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Drive Shaft
See Figure 6
1. Remove four screws (5), seal retainer (2), gaskets (4),
and stationary part of shaft seal assembly (4). Refer to
view of item 3.
2. Remove the carbon ring and the remainder of the shaft
seal from the shaft.
3. Remove shaft and bearing assembly (1).
Cam and Piston/Shoe Assembly
1. Remove the retaining ring (2, figure 2), thrust washer
(3), piston and shoe assembly (4) and creep plate (5) from
the cam (6).
2. Remove the cam from the mounting flange by carefully
tilting mounting flange on its side and removing plugs (12,
Figure 2) with O-rings (9, Figure 2) using 1⁄4-20 threaded
rod as a puller, and removing screws (10, Figure 2) attach-
ing cradle to mounting flange.
Unit Disassembly Continued Series 24, 30
8
TABLE IV Rework Limits of Wear Parts
Max. Rework
From Original Min. Dimension
24 and 30 in3Dimension After Rework
Port plate face .010" (.254 mm) .735" (18.67 mm)
Shoe retainer face .005" (.127 mm) .494" (12.55 mm)
*Piston shoe face (pocket) .002" (.051 mm)(24 in3) .018" (.457 mm)(24in3)
Creep plate face .010" (.254 mm) .365" (9.27 mm)
Face plate None Replace
* NO REWORK PERMITTED ON 30 in3SHOE.
IMPORTANT:
The port plate both sides, face finish must be 8 microinches, (0, 20 µmm) flat within .00006 (0, 0015) and parallel within
.001 (0, 025 mm) T.I.R.
The creep plate wear face finish must be 5 microinches (127 µmm), flat within .0005 (0, 012 mm) and parallel to the back-
side with .001 (0, 0254 mm) T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 µmm), and flat within .0005 (0, 012 mm) (must not be
convex).
The piston shoes wear face finish must be 30 microinches (760 µmm), and must be lapped in a set with the retainer plate,
all shoe sole thicknesses to be within .001 (0, 0254 mm) after lapping. The maximum permissible shoe and piston axial
looseness is .010 (0, 254 mm).
The special retaining ring service kit (S23-12629) may be required to control shoe holddown clearance.
Removal & Replacement Tool for H.D. Lock Screw — Barrel H.D. Adjustment Tool
Disassembly & Assembly Tool Drawings
T1 T2
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Drive Shaft Assembly
Figure 1
1. Slide the bearing (2) over the short end of the shaft and
seat against the shoulder.
Support only the inner race of
the bearing and press on the long end of the shaft to install
bearing.
DO NOT USE EXCESSIVE FORCE. USE EXTREME
CARE PASSING THE RING OVER THE SEAL SURFACE.
2. Install the retaining ring (3) in the groove. Be sure that
the ring is fully seated.
9
Assembly Procedures Series 24, 30
S23-12474 #3 Drive Shaft Assembly (spline)
S23-12475 #2 Drive Shaft Assembly (w/keyway) QTY
ITEM DESCRIPTION PART NO. #1 #2
1 #3 (splined) Drive shaft 033-91139 1 —
#2 (keyed) Drive shaft 033-91140 — 1
2 Shaft bearing 230-82213 1 1
3 Retaining ring 033-71712 1 1
4 Square key 033-71910 — 1
FIGURE 1
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Barrel, Cam to Mounting Flange
Figure 2
3. Position the mounting flange (8) with the large open end
facing up and install two dowel pins (7) in the cradle mount-
ing surface and one-3/8" (9.52 mm) dia. dowel pin (11) in
the outer edge of the flange.
4. Install the cam (6) over the dowel pins (7) in the mount-
ing flange. Position cam so that the thick part of the cam is
on the same side as the 3/8" (9.52 mm) dowel (11).
5. With cam installed, tilt mounting flange on its side and
secure with two Soc. Hd. cap screws (10). Torque to 50 ft.-
lbs. (67.8 N•m).
6. Insert plugs (12) with o-rings (9) into Soc. Hd. cap screw
(9) c'bores. Be sure tapped hole in plug (12) is visible after
installation, this is used for removal.
7 Install shaft and bearing assembly (1) Figure 6 (either
splined or keyed as specified) by inserting shaft through
bores, a few light taps are required on the bearing outer
race to completely engage and seat bearing.
NOTE: Do not tap on end of shaft.
Seal Assembly
Figure 6
NOTE: See warning information below
1. The shaft seal is available only as a complete assem -
bly. Prior to installation examine all the seal parts. Handle
the lapped seal seat and the carbon ring with extreme care.
Both parts must be free of scratches, cracks or other dam-
age.
2. Install the spring retainer (e) over the shaft and against
the bearing retaining ring.
3. Install the spring (d) against the retainer.
4. Apply oil to the inner surface of the rubber friction ring
(f) and install the shell containing the friction and the car -
bon ring (c) over the shaft with the carbon ring exposed.
5. Apply grease to the square section rubber seal (a) and
install on the seat.
6. Install the seat and seal in the seal retainer (2). The
lapped surface of the seat must face the carbon ring.
7. Install the seal retainer assembly and O-ring (4) over the
shaft with the lapped surface against the carbon face.
8. Install the screws (5) and the seal retainer.
9. Depress the seal retainer only far enough to start the
screws and tighten evenly in a criss-cross pattern. Torque
to 30 ft.-lbs. (40.8 N•m).
Seal Replacement
Figure 6
NOTE: 24 Series only–To replace shaft seal only.
1. Remove unit for disassembly.
2. Remove retaining ring (8, Fig. 3).
3. Replace shaft seal. (Follow seal assembly in reverse
order.)
4. After seal is replaced re-install retaining ring (8, Fig. 3).
CAUTION Failure to follow these instructions may result
in pump failure.
Mechanical shaft seal assembly procedure
Warning: When installing a new mechanical shaft seal,
exercise care to insure that all of the parts fit together prop-
erly. This is particularly important if the seal was once
assembled and disassembled for some reason. If the rub-
ber boot, item 4, grips the shaft and doesn't slide on the
shaft, as it is disassembled, then the spring, item 7, can
disengage the shell, item 5, from the band, item 6, so that
they do not re-engage properly when reassembled. Be sure
the shell and the band are properly engaged before
reassembling the seal, and stays engaged during assem-
bly.
Note:
Lubricate seal and shaft with clean hydraulic fluid of the
same type that will be used in the system.
Assembly Procedures Continued Series 24, 30
10
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11
Assembly Procedures Continued Series 24, 30
Piston/Shoe Assembly to Cam
Figure 2
1. Return the mounting flange to an upright position.
2. Install creep plate (5) over center post on cam (6) cham-
fered end first.
3. Insert piston and shoes into retainer and install entire
assembly (4) against creep plate.
4. Install thrust washer (3), over center post of cam and
against shoe retainer. Grooved side of washer must face
shoe retainer.
5. Install the thickest retaining ring (2) that will fit in the
groove on the rocker cam center post which will allow a
maximum clearance of .002-.005" (.05-.13 mm) between
the creep plate and shoe faces. To check this clearance,
grasp one piston and lift and lift until tight against shoe
retainer. Insert thickness gage. If this clearance is not cor-
rect, select the appropriate retaining ring and repeat the
checking procedure.
PARTS LIST FOR FIGURE 2
ITEM DESCRIPTION PART NO. QTY.
1 Barrel & aux. shaft assy. See Fig. 3 1
2 Retaining ring — use one only 1
.089/.087 thick w/yellow dot (2.26/2.21 mm) 033-71716
.087/.085 thick w/green dot (2.21/2.16 mm) 033-71717
.083/.081 thick w/red dot (2.11/2.06 mm) 033-71718
.081/.079 thick w/blue dot (2.06/2.01 mm) 033-59746
.085/.083 thick w/white dot (2.16/2.11 mm) 033-91130
Retaining ring service kit S23-12629
3 Thrust washer 033-59805 1
4 Piston & shoe assy. P24 S13-44470 1
Piston & shoe assy. P30 S23-12684
5 Creep plate 033-71747 1
6 Cam 033-91148 1
7 Dowel pin 324-24028 2
8 Mounting flange 033-91137 1
9 O-ring 671-00111 2
10 Soc. Hd. cap screw 358-16260 2
11 Dowel pin 324-22416 1
12 Plug 033-57475 2
NOTE: If metallic thickness gage is used, caution
should be exercised not to scratch shoe face. There
are five different retaining rings available for this tol-
erance. Each retaining ring is marked: .081/079"
(2.06/2.01 mm) thick, blue dot; .083/.081" (2.11/2.06
mm) thick, red dot; .087/.085" (2.21/2.16 mm) thick,
green dot; .089/.087" (2.26/2.21 mm) thick, yellow
dot; and .085-.083 (2.16/2.11mm) white dot. The pis-
ton and shoe assembly must be free to rotate 360 °
by hand.
Figure 2
6. Position the barrel assembly (1) directly over the pis-
tons. Starting with the uppermost piston, guide them one
at a time into the barrel bores.
NOTE: Support the barrel on the main shaft but tilted
slightly so as not to allow the barrel to drop and fully
engage the barrel and shaft splines, now the holddown
assembly can be installed without any load against it.
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Assembly Procedures Continued Series 24, 30
Barrel and Auxiliary Shaft Assembly
Figure 3 (24 Series)
1. Install auxiliary shaft (2) large spline end first into coun-
terbore in face of barrel and engage barrel spline.
2. Install spherical seat (3) round or spherical face up into
counterbore in face of barrel.
3. Install spring retainer (4) socket side down into counter-
bore, install spring (5) and seat against spring retainer.
4. Thread holddown adjustment screw (6) into counterbore
approx. four threads.
5. Tilt barrel vertically and engage main shaft spline with
the barrel spline allowing barrel to drop in place.
6. Thread holddown adjusting screw (6) into counterbore
until it is flush to .060" (1.52 mm) max. below barrel face.
12
PARTS LIST FOR FIGURE 3 (24 SERIES)
QTY
ITEM DESCRIPTION PART NO. P24P
1 Barrel & sleeve assy. 24 series only S23-12091 1
2 Auxiliary drive shaft 033-57211 1
3 Spherical seat 033-57147 2
4 Spring retainer 033-57138 1
5 Spring 033-57136 1
6 Holddown adj. screw 033-57139 1
7 Holddown adj. scr. lock 033-57241 1
8 Holddown lock retaining ring 033-57239 1
FIGURE 3
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13
Assembly Procedures Continued Series 24, 30
Barrel and Auxiliary Shaft Assembly
Figure 3.1 (30 Series)
1. Install auxiliary shaft (2) spline end first into counterbore
in face of barrel and engage barrel spline.
2. Slide holddown spring assembly (see enlargement for
proper spring arrangement) (3) onto shaft (2).
3. Install spring retainer (4) into counterbore.
4. Thread holddown screw assembly (5) into barrel’s coun-
terbore approx. four threads.
5. Tilt barrel vertically and engage main shaft spline with
the barrel spline allowing barrel to drop in place.
6. Thread holddown screw assembly (5) into counterbore
until it is .25 (6.35 mm) below barrel face.
PARTS LIST FOR FIGURE 3.1 (30 SERIES)
QTY
ITEM DESCRIPTION PART NO. P30P
1Barrel & sleeve assy. 30 series only S23-12170 1
2 Auxiliary drive shaft 033-57935 1
3 Holddown spring 035-71713 8
4 Spring retainer 033-91138 1
5 Barrel holddown nut assy. S23-12171 1
FIGURE 3.1
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Assembly Procedures Continued Series 24, 30
S23-12566 (P24) P23-12175 (P30)
Housing Assembly
Figure 4
1. Clean housing (1) and position on a flat surface with the
large open end up.
2. Apply Loctite primer grade “T” & Loctite retaining com -
pound #609 per A.P. 01433 to bearing O.D. & bearing bore
of housing. Immediately align & press bearing into hous -
ing bore with a smooth steady force until seated. Install
socket head cap screw (3) with washer (7). Typical two
places. Torque to 30 ft. lbs. (40.8 N•m).
3. Install two dowel pins (4) in the blind holes in the control
cover pads.
4. Repeat step 3 on the opposite side of the housing.
5. Install O-ring (5) and plug (6) in the bottom of housing.
14
PARTS LIST FOR FIGURE 4
ITEM DESCRIPTION PART NO. QTY.
1Housing (P24) 033-57150 1
Housing (P30) 033-57925 1
2 Bearing 033-93046 1
3 Screw Soc Head Cap 358-14106 2
5⁄16 x 18 x 5⁄8w/Nylock
4 Dowel pin 324-21608 4
5 O-ring 691-00920 1
6 Plug 488-35019 1
7 Washer 11⁄32 (8.73 mm) 345-10020 2
steel
FIGURE 4
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15
Assembly Procedures Continued Series 24, 30
Housing Assembly Installation
Figure 5
1. Install gasket (3) over the dowel pin in the mounting
flange. Do not use gasket compound.
2. Install the housing assembly (4) over the barrel and aux-
iliary shaft assembly.
3. Insert two Hex. Hd. cap screws (5) through mounting
flange and into housing. Torque to 100 ft.-lbs. (135.6 N•m).
These must be fully torqued later when main bolts are in
place.
4. Install face plate pins (1) in the holes provided in the bar-
rel face.
5. Apply clean heavy grease to the surface of the barrel
and install the face plate (2) over the face plate pins. The
surfaces must be absolutely free of scratches, dust or dirt
to prevent excessive leakage. Lubricate pistons with clean
system fluid through the holes in the face plate.
CAUTION: The face plate has a black break-in coat -
ing on top of bronze which is bonded to a steel back -
ing. Lightly sand the edge of the plate to identify the
bronze coated side. The bronze side should go toward
the port plate.
PARTS LIST FOR FIGURE 5
ITEM DESCRIPTION PART NO. QTY.
1Face plate pins 033-59747 3
2 Barrel face plate (P24) 033-71748 1
Barrel face plate (P30) 033-57571 1
3 Housing gasket 033-91082 1
4 Housing assembly See Fig. 4 1
5 Hex Hd. screws 306-40009 2
FIGURE 5
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Assembly Procedures
Continued
Series 24, 30
16
FIGURE 6
PARTS LIST FOR FIGURE 6
ITEM DESCRIPTION PART NO. QTY.
1No. 3 Splined shaft assy. S23-12474 1
(See fig. 1)
No. 2 Keyed shaft assy. S23-12475
(See fig. 1)
2 Seal retainer 033-57472
3 Shaft seal 623-00015 1
4 Seal retainer O-ring 671-00246 1
5 Hex. head screw 306-40123 4
6 Nyltite washer 631-45007 8
7 Hex. hd. washer screw 353-25039 8
8 Cover 033-53252 2
9 Gasket 033-91058 2
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17
Assembly Procedures Continued Series 24, 30
Port Block Installation
Figure 7
1. Position the motor with open end of the housing assem-
bly (6) facing up. Install new gasket (5) on the housing. Do
not use gasket compound.
2. Install two port plate pins (3) in the face of the port block
(2) and the dowel pins (7) into mounting surface of port
block.
3. Insert lifting eyes into tapped holes in each system port
mounting surface.
4. Apply heavy grease to the rear of the port plate (4) and
install over the port plate pins.
5. Temporarily attach port plate to port block by inserting
a cord through one of the 2" (50.8 mm) dia. ports down
through the port block port, around arcuate divider in port
plate, back through port block and tie ends of the cord to
lifting eye. Repeat this step to the other side of the port
plate.
6. Install the port block over the auxiliary shaft and posi -
tion onto dowel pins.
7. Install the six bolts (1 & 8) with washers (9, 10). Do not
drop the bolts in place as the threads may be damaged.
Torque bolts evenly. Torque bolts (1) in 50 lb. (67.8 N•m)
increments to 450 ft.-lbs. (610 N•m) and the two bolts (8)
to 120 ft.-lbs. (163 N•m) tightening in turn all six bolts.
Re-torque the two bolts (5) Fig. 5 to 120 ft.-lbs (163 N•m).
PARTS LIST FOR FIGURE 7
ITEM DESCRIPTION PART NO. QTY.
1Hex head cap screw (P24P) 306-40221 4
Hex head cap screw (P30P) 306-40230 4
2 Port block 033-57898 1
3 Port plate pins 324-21610 2
4 Port plate (24) 033-71751 1
Port plate (30) 033-91149 1
5 Port block gasket 033-91085 1
6 Housing assembly (24) S23-12566 1
Housing assembly (30) S23-12175 1
7 Dowel pin 033-57020 2
8 Hex head cap screw 306-40022 2
9 Washer, Hdn. St’l. 350-10136 2
10 Washer, Hdn. St’l. 350-10135 4
11 Seal/shuttle valve 691-10016 3
Seal/cover 691-10014 2
Seal/cover 691-10019 1
12 Shuttle valve/2 orif. S13-48776 1
Shuttle valve/Int. dr. S13-48273
Cover 033-71649
13 Screw-hex hd./shuttle 306-48273 3
Screw-hex hd./cover 306-40071
14 O-ring 671-00147 1
15 End cover 033-72100 1
16 Retaining ring 356-65082 1
17 O-ring 691-00906 1
18 Hex. soc. plug 488-35041 1
19 O-ring 691-00920 1
20 Plug 488-35019 1
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Assembly Procedures
Continued
Series 24, 30
18
FIGURE 7
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19
Barrel Holddown
Figure 3 & 7 (24 Series)
1. Use special tool T2 and slip over auxiliary shaft and
engage the holes in the holddown adjusting screw (6, fig-
ure 3). Carefully tighten until screw bottoms out.
2. Remove special tool T2 and sight through holddown screw
and note where tooth of auxiliary shaft spline is located.
3. Back off holddown screw (loosen) 5 to 6 spline teeth on
auxiliary shaft (approx. 135°).
4. Barrel lift-off is now set at .030-.036 (.76-.91 mm).
5. Use special tool T1 and thread holddown adjusting screw
lock (7, figure 3) into holddown adjusting screw.Torque to
30 ft.-lbs. (40.7 N•m).
6. Slip holddown lock retaining ring (8, figure 3) over aux-
iliary shaft into groove which is located 2
3⁄16" (55.2 mm) from
end of shaft.
7. Untie cords holding port plate and remove.
Barrel Holddown
Figure 3.1 & 7 (30 Series)
1. Use special tool T2 and slip over auxiliary shaft
and engage dowels into holddown screw assembly, (5,
Figure 3.1). Carefully tighten clockwise until holddown
screw assembly bottoms out.
2. Back off holddown screw assembly 140°, counter-clock-
wise.
3. Barrel lift-off is now set at .032" (.81 mm).
4. Remove spanner wrench. Rotate drive shaft, item 31, to
check if any binding occurs.
5. Lock holddown screw assembly in place by tightening
the six socket head cap screws gradually in the following
torque sequence until 65 in.-lbs. (7.4 N•m) torque is
reached.
**Torque sequence for locking holddown screw assembly.
6. Untie cords holding port plate and remove.
End Cover
Figure 7
1. Apply a light film of oil or grease to O-ring (14) and place
in groove in end cover (15). Insert end cover (15) into bore
of port block.
2. Install retaining ring (16) into groove.
NOTE: If barrel holddown has to be reset for any rea-
son all six socket head cap screws must be loosened
gradually in the same order they were tightened. Do
not remove socket head screws completely. Use the
#10-32 UNF tapped holes in the insert to disengage
insert from holddown screw assembly. Insert must be
loose before resetting barrel holddown.
NOTE: The main drive shaft must be held to prevent
barrel assembly from turning. If barrel assembly turns,
the adjustment cannot be made.
NOTE: Tapped hole in holddown screw must line up
with space between spline teeth.
NOTE: The main drive shaft must be held to prevent
barrel assembly from turning. If barrel assembly turns,
the adjustment cannot be made.
Assembly Procedures Continued Series 24, 30
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Shuttle Valve Assembly Series 24, 30
20
Shuttle Valve Assembly Internal Drain
1. Place valve assembly (12, fig. 7) in a horizontal position
with the O-ring groove up.
2. Press seat (11) in the .500" (12.7 mm) diameter bore
until it is flush with the body surface.
3. Install spring centering washer (4) over each end of
spool.
5. Install springs (3) over ends of spool and into sockets of
centering washers.
6. Lubricate O-rings (2) and install over plugs (1). Install
the plugs over springs and into body.
7. Install spool (10) in bore against seat (11).
8. Install spring (9) in spool (10).
9. Lubricate O-ring (8) and install on groove of plug (7) on
internally drained shuttle.
10. Install plug (7) over spring (9) and tighten.
11. Install seal (11, fig. 7) in counterbore in center of shut-
tle valve assembly. Hold in place with a coating of grease.
Install the two seals in remaining counterbores.
12. Install orifices, (15) if required.
13. Install the shuttle valve assembly on port block pad and
secure with screws (13). Torque screws to 20 ft.-lbs. (27.2
N•m)
FIGURE 8
S13-48273 Assembly, Shuttle Valve without orifices
S13-48776 Assembly, Shuttle Valve with orifices
Item Qty. Part No. Description
1 2 488-35002 Plug
2 2 691-00908 O-ring
3 2 033-70515 Spring
4 2 033-70495 Washer, spring centered
5 1 033-70529 Spool
6 1 033-53117 Body
7 1 033-72129 Plug
8 1 691-00906 O-ring
Item Qty. Part No. Description
9 1 033-71923 Spring, relief valve
10 1 033-71925 Spool, relief valve
11 1 033-53154 Seat
12 3 691-10016 Tetraseal
13 3 306-48273 Screws, 5/16-18 x 2 3/4
14 2 345-20004 Shim washer
15 2 033-53523 Orifice .78 (mm) (optional)
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