Denison Hydraulics P11S Series Operating and installation instructions

DENISON HYDRAULICS
axial piston variable displacement with auxiliary
package external replenishing pump Goldcup
series P11S & P14S C mod
service information
Publ. S1-AM023-C Revised 6/04
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PAGE
seal kits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
typical characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
fluid connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4
maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
comparison of solid contamination classification systems - - - - - - - - - - - - - - - - - - -5
start up procedures- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6
disassembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
rework of wear part-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9
assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
drive shaft & bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
barrel & auxiliary drive shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
rocker cam assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
piston/shoe/retainer assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13
mtg. flg./cradle/barrel/aux. shaft assy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13
housing assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
hsg./end cap/cam/barrel assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
port block assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
port block/housing assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
gerotor & barrel holddown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16
valve block assembly (after 7-93) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18
valve block assembly for special mounting of servovalve (after 7-93) - - - - - - - - -20
adapter assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
check valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
shuttle valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
pilot valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24
shaft & seal installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26
A mod shaft seal replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
B mod shaft seal replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
counterbalance servo stem installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
control cover installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
instructions for replenishing isolation plug - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
port locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
gage pressure ranges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
conversion of A or B mod to C mod - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
test procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -30
installation drawing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
hydraulic circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34
pump key sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36
conversion formulas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -37
part no.
pump seal kit complete, std. valve block, less control CW rotation S23-15245
pump seal kit complete, std. valve block, less control CCW rotation S23-15246
shaft seal - outer 620-82101
shaft seal - inner CW rotation 620-82104
shaft seal - inner CCW rotation 620-82105
std. valve block seal kit S23-00135
hi IQ valve block seal kit S23-02446
shuttle valve seal kit S23-15089
1** thru 6**control S23-02303
6A control S23-02305
8** control S23-15156
9**control S23-15157-5
output indicator, 1** and 4A control S23-02304
**4 torque limiter S23-02302
CONTENTS
SEAL KITS
2
Note: Throughout this bulletin, metric quantities are indicated in parenthesis, and deci-
mal point is designated by a period
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Specification Term Goldcup 11 Goldcup 14
• displacement at max. angle in3/rev. 11.00 14.00
cm3/rev. (180) (229)
• pressure continuous psi 5000 5000
bar (345) (345)
• pressure intermittent psi 6000 6000
bar (414) (414)
• speed, max. continuous-full stroke RPM 2400 2400
• speed, max. continuous-half stroke RPM 2800 2800
• flow, ports A or B @ 1800 RPM GPM 85.7 109.1
(theoretical) l/min. (324.4) (412.9)
• flow, int. aux. pump @ 1800 RPM GPM 16.7 16.7
(theoretical) l/min. (63.1) (63.1)
• flow, ext. aux. pump @ 1800 RPM GPM 9.8 9.8
(theoretical) l/min. (37.2) (37.2)
• replenish pressure psi 330-370 330-370
minus case pressure bar (22,76-25,52) (22,76-25,52)
• servo pressure minus case psi 490-790 490-790
pressure @ zero discharge pressure bar (33.79-54.48) (33.79-54.48)
• max. continuous case pressure psi 75 75
bar (5.2) (5.2)
• max. intermittent case pressure psi 125 125
bar (8.6) (8.6)
• control on - stroke response time sec. 1.5 1.5
• typ. compensator off - stroke time sec. .07 .07
• mounting-4 bolt flange SAE E E
• shaft-spline or keyed SAE E E
• weight w/spg. ctd. rotary servo lbs. 485 485
kg. (220) (220)
PORT LOCATIONS AND SIZES
• ports A& B (system) SAE code 62 split flange in. 1-1/2
mm (38.1)
• port AG, BG (A&B system gage) straight thread O-ring seal SAE -6
• port C (aux. pump inlet) SAE code 61 split flange in. 1-1/4
mm (31.8)
• port D1 (aux.case drain) straight thread O-ring seal SAE -16
• port D2 (case drain) 370flared SAE -16
• port D3 (repl relief drain) straight thread O-ring seal SAE -16
• port DG (case gage) straight thread O-ring seal SAE -6
• port DG2 (bearing flush) straight thread O-ring seal SAE -4
• port DG3 (air bleed) straight thread O-ring seal SAE -4
• port DS (shuttle repl pilot drain) straight thread O-ring seal SAE -4
• port FA, FB (control pressures) straight thread O-ring seal SAE -6
• port G (servo pressure both sides) st. thd. O ring seal SAE -4
• port G2 (servo pressure A side) straight thread O-ring seal SAE -8
• port I (external aux. pump inlet) SAE code 61 split flange in. 1-1/4
mm (38.1)
• port J (internal aux. pump outlet) SAE -8
• port J1 (internal aux. pump outlet) SAE -10
• port K (aux. repl. inlet) straight thread O-ring seal SAE -16
• port KG (repl. gage) straight thread O-ring seal SAE -6
• port SD (seal drain) straight thread O-ring seal SAE -4
• port V (common vent) straight thread O-ring seal SAE -4
• port VA, VB (A&B individual vents) straight thread O-ring seal SAE -4
INSTALLATION
TYPICAL CHARACTERISTICS
FLUID CONNECTIONS
3
J1
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The DENISON HYDRAULICS Goldcup 11 and Goldcup 14 axial piston pumps feature
advance design concepts which are time proven and provide for advance pumping and
control concepts. The instructions contained in this manual cover complete disassem-
bly and re-assembly of the unit. Before proceeding with the disassembly or re-assem-
bly of any unit, this manual should be studied in order to become familiar with proper
order and parts nomenclature.
The use of a rocker cam to control the pump displacement provides a small package
size, reduces wear, and speeds control response. The control vane actuator elimi-
nates linkage and backlash inherent in typical stroking cylinder designs.
Standard controls for the Goldcup units are rotary servo and compensator over-ride.
Additional optional controls are also available.
This pump is designed to operate in any position The mounting hub and four bolt
mounting flange are in full conformance with SAE standard. The pump shaft must be
in alignment with the shaft of the driven load and should be checked with a dial indica-
tor. The mounting pad or adapter into which the fluid pump pilots must be concentric
with the pump shaft to prevent bearing failure. This concentricity is particularly impor-
tant if the shaft is rigidly connected to the driven load without a flexible coupling.
Splined: The shafts will accept a maximum misalignment of .006”TIR (0.15 mm).
Angular misalignment at the male and female spline axes must be less than ± .002”
per inch radius (0.002 mm per mm radius). The coupling interface must be lubricated.
DENISON HYDRAULICS recommends lithium- molybdenum disulfide or similar
grease. The female coupling should be hardened to 27-45 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”(0.75-1 mm) at
450to clear radii that exist in the keyway.
Keyed shafts will accept a side load of 1000 lb. (454 kg) at the center of the key, with a
B10 life of 10000 hours at 1800 RPM and 40 psi case pressure.
Connect inlet and outlet lines to the port block of the pump.
The maximum case pressure is 75 PSI (5.7 bar) continuous, 125 PSI (8.6 bar) inter-
mittent. A 5 PSI (0.3 bar) case pressure check valve is included in the normal case
drain port, D2, to be certain the case is filled with oil at all times.
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, tubing, or hose must be
adequate size and strength to assure free flow through the pump. An undersize inlet
line will prevent the pump from operating at full rated speed. An undersize outlet line
will create back pressure and cause heat generation. Flexible hose lines are recom-
mended. If rigid piping is used, the workmanship must be accurate to eliminate strain
on the pump 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 equiv-
alent before installing pump. Make sure the entire hydraulic system is free of dirt, lint,
scale, or other foreign material. Flushing with a large temporary high pressure loop fil-
ter is recommended.
These hydraulic products are designed to give long dependable service when properly
applied and their systems properly maintained. These general instructions apply to
typical systems. Specific instructions for particular equipment can be developed from
them.
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-aer-
ating properties as described in DENISON HYDRAULICS standard HF-1. Where anti-
wear additive fluids are specified, see DENISON HYDRAULICS standard HF-0.
Max. at cold start - 7500 SUS (1600 cSt)
(at low pressure, low flow, and if possible, 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)
INSTALLATION
INTRODUCTION
DESCRIPTION
MOUNTING
SHAFT INFORMATION
SIDE LOAD
PIPING
SERVICE INFORMATION
RECOMMENDED FLUIDS
VISCOSITY
4
CAUTION: Do not use galvanized pipe. Galvanized coating can flake off with contin-
ued use.
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90 V.I. minimum. Higher values extend the range of operating temperature but may
reduce the service life of the fluid.
Determined by the viscosity characteristics of the fluid used. Because high tempera-
tures degrade seals, reduce the service life of the fluid and create hazards, fluid tem-
peratures should not exceed 1800F (820C) at the case drain.
Some applications require fire-resistant fluids. They will give good service if the sys-
tem 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 information.
This pump is self-lubricating and preventative maintenance is limited to keeping sys-
tem fluid clean by changing filters frequently. Keep all fittings and screws tight. Do not
operate at pressures and speeds in excess of the recommended limit. If the pump
does not operate properly, check the troubleshooting chart before attempting to over-
haul the unit. Overhauling is relatively simple and may be accomplished by referring to
the disassembly, rework limits of wear parts, and assembly procedures.
Fluid must be cleaned before and continuously during operation, by filters that maintain
a cleanliness level of NAS 1638 class 8 (class 9 for 15 micron and smaller). 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 levels 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.
•Read and understand the instruction manual. Identify components and their function.
•Visually inspect components and lines for possible damage.
•Check reservoir for cleanliness and drain and clean as required.
•Check fluid level and fill as required with filtered fluid at least as clean as that
recomended. Fill pump case with clean oil prior to starting.
•Check alignment of drive.
•Check oil cooler and activate it, If included in circuit.
•Reduce pressure settings of relief valve. Make sure accurate pressure readings can
be made at appropriate places.
•If solenoids are included in system, check for actuation.
•Start pump drive. Make sure pump and motor fill properly.
INSTALLATION
VISCOSITY INDEX
TEMPERATURE
ALTERNATE FLUIDS
MAINTENANCE
FLUID CLEANLINESS
START UP PROCEDURES FOR
NEW INSTALLATION
5
COMPARISON OF SOLID CONTAMINATION CLASSIFICATION SYSTEM
NATIONAL AERONAUTICS STANDARD (NAS) 1638
class
00 0 1 2 3 4 5 6 7 8 9 10 11 12
5-15µm 125 250 500 1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000
particle 15-25µm 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400
size 25-50µm 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400
range 50-100µm 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760
>100µm 0 0 1 1 2 4 8 16 32 64 128 256 512 1024
maximum >5µm 152 304 609 1217 2432 4864 9731 19462 38924 77849 155698 311396 622792 1245584
particles >15µm 27 54 109 217 432 864 1731 3462 6924 13849 27698 55396 110792 221584
ISO:DIS 4406; SAE J1165
iso solid contaminant code
8/5 9/6 10/7 11/8 12/9 13/10 14/11 15/12 16/13 17/14 18/15 19/16 20/17 21/18 22/19
maximum >5µm 250 500 1000 2000 4000 8000 16000 32000 64000 130000 250000 500000 1000000 2000000 4000000
particles >15µm 32 64 130 250 500 1000 2000 4000 8000 16000 32000 64000 130000 250000 500000
NOTES: All measurements are for a 100 ml sample size.
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TROUBLESHOOTING
START UP PROCEDURES FOR
NEW INSTALLATION
(continued)
TROUBLESHOOTING
6
•Bleed system of air. Recheck fluid level.
•Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
•Increase pressure settings gradually in steps. Check for leaks in all lines especially
in pump and motor inlet lines.
•Make correct pressure adjustments.
•Gradually increase speed. Be alert for trouble as indicated by changes in sounds,
system shocks and air in fluid.
•Equipment is operational.
Component problems and circuit problems are often interrelated. An improper circuit
may operate with apparent success but will cause failure of a particular component
within it. The component failure is the effect, not the cause of the problem
This general guide is offered to help in locating and eliminating the cause of problems
by studying their effects.
effect of trouble possible cause fault which needs remedy
noisy pump air in fluid leak in suction line
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 fluid too cold
rotating group fluid too viscous
fluid too heavy
shaft speed too high
suction line too small
suction strainer too small
suction strainer too dirty
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 piston and shoe looseness or failure
in pump bearing failure
incorrect port plate selection or index
eroded or worn parts in the displacement control
erosion on barrel air in fluid see above
ports and port cavitation see above
plate
high wear in excessive loads reduce pressure settings
pump and motor reduce speeds
contaminant par- improper filter maintenance
ticles in fluid filters too coarse
introduction of dirt fluid to system
reservoir openings
improper reservoir breather
improper line replacement
improper fluid fluid too thin or thick for operating temperature
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
unwanted water condensation
in fluid faulty breather/strainer
heat exchanger leakage
faulty clean-up practice
water in makeup fluid
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effect of trouble possible cause fault which needs remedy
pressure shocks cogging load mechanical considerations
worn relief valve needed repairs
worn compensa- needed repairs
tor
slow response in replace or relocate
check valves
servo pressure increase pressure and check pressure drop
too low to through servo filter
maintain firm
control
excessive de- improve decompression control
compression
energy rates
excessive line reduce line size or lengths
capacitance eliminate hose
(line volume,
line stretch,
accumulator
effects)
barrel blow-off re-check pump hold-down, rotating group, drain
pressure
heating of fluid excessive pump recheck case drain flow and repair as required
or motor leak- fluid too thin
age improper assembly, port timing
relief valve set too low (compared to load or to compensator)
instability caused by back pressure, worn parts
compensator set too high (compared to relief)
worn parts
pump too large select smaller pump displacement
for fluid needs
heat exchanger water turned off or too little flow
water too hot
fan clogged or restricted
efficiency reduced by mud or scale deposts
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
It is essential to make certain that the case (pump housing) is as full of fluid as possi-
ble and remains full during operation and at rest. Always fill to the highest available
point. Remove a plug or screw and allow the oil to escape through this point.
Recommended fill ports:
Mounting orientation vertical, shaft up. D1 (drain) port in housing.
Vent DG3 port in mounting flange (new units) or one of the upper screws which attach
the control. See installation drawing.
Mounting orientation vertical, shaft down, horizontal, drain ports to the side: D1 or D2
(drain) port in housing. Vent DG (case gage) port in port block. Vent DG3 port in
mounting flange (if on correct side) or screw from the upper control cover.
CAUTION: The shaft and seal area of a rear mounted pump will be exposed to the
primary pump’s case pressure. This can cause damage to the rear mounted pump’s
shaft seal. When using an external pump other than the Denison vane pump normally
supplied with the rear drive “S”version pump, note the following:
For a rear mounted pump without external drain, modification of the pump’s shaft seal
will be required if case pressure exceeds that which the rear seal can withstand. If the
rear mounted pump contains a case drain, the primary and the rear mounted pump
case drains may be connected to a common line to equalize the pressures on the
shaft seal.
TROUBLESHOOTING
FILLING CASE
SPECIAL INSTRUCTIONS FOR
MOUNTING AUXILIARY PUMP
7
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The instructions contained in this section cover a complete teardown of the subject
pump. Disassemble only as far as necessary to replace or repair any worn parts.
Position pump unit so that valve block assembly is on top. A bench or similar suitable
surface capable of supporting unit should be used. Disassembly area should be clean.
See figure 16. Remove the eight hex head cap screws (18) and lift the entire block
assembly from the port block.
See figure 10. Remove the four screws (43) and remove the retainer plate (42).
Remove the seats (27 & 28), poppets (30 & 31), and springs (32, 33 & 35).
Remove the plugs (20, 23 & 25) and pin (21). Refer to servo strainer assembly (14).
Remove the SHCS retaining the strainer, remove the strainer and strainer support
Remove housing (8) and O-ring (9). Remove items (6), (7), and (45) as a unit. Insert
a small brass rod through the hole in the housing and tap out piston (10) and O-ring
(11).
Remove spring (12) and cone (13). Remove seat (5) and O-ring (4). NOTE: Seat is
made for hex wrenching. Use 1/2”6 point socket with 1/4”drive.
Remove replenishing relief valve (36). (Replenishing relief valve is located behind plug
(25). Inspect orifices (3) to insure they are open. Do not remove unless damage or
clogging is apparent.
Do not remove spring pins (26) and (46) unless replacements are needed.
See figure 16. Remove the four screws (15) from the side cover (17) and remove the
input shear seal control assembly.
Remove the four screws (15) from the side cover (16) and remove the counter balance
shear seal control assembly.
Remove the screws (13) and (10) and remove the balance stem (9) and balance plate
(11).
Remove two screws (21) and remove external pump (22).
Remove four screws (25) and remove shuttle valve (26).
Remove four screws (9, fig. 12) and remove adapter (24).
See figure 9. Remove locking ring (18), pin (17), hold-down nut (16), insert (19),
thrust washers (13), bearing (14) and seal ring (15).
Remove pressure plate (12), “O”rings (10) and (11), and side plate assembly (9).
Remove servo gerotor assembly (7), dowel pin (8), key (6), and center port plate (4).
Remove replenishing gerotor (3), key (2) and side plate (1).
See figure 8. Remove four screws (1) that secure the port block (2) to the housing
(6). Use caution when removing screws on valve block side to prevent marring valve
block face.
Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3).
Note: port plate will in some instances adhere to port block upon disassembly.
See figure 7. Remove the check valve assemblies (7) from the port block.
Remove the needle bearing (2) from the port block.
Remove plugs (8,10 and 12).
Remove two screws (4), lockwashers (5), check rings (3) and clamps (6).
Remove face plate and pins (2 and 1, fig. 6) from face of barrel assembly.
Remove the barrel assembly (1, fig. 4) by grasping the auxiliary shaft and lifting the
complete assembly out of the housing.
UNIT DISASSEMBLY
INTRODUCTION
DISASSEMBLY
VALVE BLOCK
CONTROLS
EXTERNAL PUMP, SHUTTLE
VALVE AND REAR ADAPTER
BARREL HOLDDOWN AND
GEROTOR ASSEMBLY
PORT BLOCK
BARREL AND AUXILIARY
SHAFT
8
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See figure 16. Remove bearing pre-load spring (27). Remove the four screws (8) and
gaskets (7). Remove seal retainer (6), and shaft assembly (1) from pump. Note:
Version “A”pumps contain a mechanical shaft seal. Replacement kits S23-15218 (CW
rotation) or S23-15349 (CCW rotation) contain all the parts to modify earlier models to
the version C design.
After shaft assembly has been removed, position the unit on end with the mounting
flange turned down.
Push the ends of the small tube lines away from the housing.
Lift the housing from the mounting flange. Remove the gasket and locating sleeves
from the mounting flange.
Do not remove the spring pins and the bearing from the housing unless the bearing is
damaged and must be replaced.
See figure 4. Remove the complete assembly from the mounting cap and position on
a clean flat surface with the two tubes (2) in a horizontal position and located at the
top. Mark the cam (24) and cradle (20) as indicated in figure 3. These marks will
assure re-assembly in the same position.
Carefully remove the small tube lines (5) and (6) from the cradle. Caution: do not
bend these lines
See figure 3. Position the assembly in an upright position on the flat surface of the
cradle (19). Remove the retaining ring (1) thrust washer (2) and bearing (3). Remove
the piston and shoe assembly (4) and the creep plate (5) from the cam (22). Carefully
remove the two set screws (12) and two screws (9) that secure the servo plate (10) to
the servo stem (6). Remove the servo input parts (6, 7 and 8).
Remove the four screws (11) and four screws (13) from the control covers (14R) and
(14L). Remove the four dowel pins (15) and remove the two chambers (16). Remove
the two special seals (18) and the four steel balls (17). Remove the two vane seal car-
tridge assemblies (25) and the four holddown vanes (24) and springs (23) from the
rocker cam (22).
Remove the rocker cam (22) from the cradle (19). Caution: Do not remove the plugs
from the rocker cam.
max. rework
11 and 14 in3 from original min. dimension after rework
port plate face .010“(0.254 mm) 705”(17.9 mm)
shoe retainer face .005”(0.127 mm) .432”(10.97 mm)
piston shoe face (pocket) .010”(0.254 mm) .010”(0.254 mm)
creep plate face .010”(0.254 mm) .240”(6.1 mm)
face plate none replace
IMPORTANT:
The port plate finish must be 25 microinches (635 µmm) both faces, flat within .00006”
(0.0015 mm) and parallel within .001”(0.0254 mm) T.I.R.
The creep plate wear face finish must be 10 microinches (254 µmm), flat within .0002”
(0.0508 mm) and parallel to the backside within .0005”(0.0127 mm) T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 µmm) and flat within
.0015”(0.0381 mm). (Must not be convex).
The piston shoes wear face finish must be 5 microinches (127 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)
UNIT DISASSEMBLY
DRIVE SHAFT
HOUSING
ROCKER CAM AND CONTROL
STROKING ASSEMBLY
REWORK LIMITS OF WEAR
PARTS
9
The special retaining ring service kit (S23-12547) may be required to control shoe
holddown clearance
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CLEANING AND INSPECTION
DRIVE SHAFT AND BEARING
FIGURE 1
BARREL AND AUXILIARY
DRIVE SHAFT
FIGURE 2
barrel and auxiliary drive shaft
All parts must be inspected and be free of material defects, dirt, scratches or any for-
eign material.
All parts must be cleaned with a suitable cleaning solvent and all holes and passages
blown out with dry, clean, compressed air. After cleaning and inspection, all parts must
be covered with a light film of oil and protected from dirt and moisture. Excessive han-
dling of internal parts should be avoided prior to assembly.
During assembly, lapped and ground surfaces must be lubricated with clean oil and
protected from nicks or surface damage.
See Figure 1. Press the bearing (2) over the end of the shaft and seat against the
shoulder. Support only the inner race of the bearing and press on the coupling end of
the shaft. Caution: Do not use excessive force.
Install retaining ring (3) in the retaining ring groove. Be sure that ring is fully seated.
PARTS LIST FOR FIGURE 1
S23-15212 DESIGN C DRIVE SHAFT ASSEMBLY (SPLINED)
S23-15213 DESIGN C DRIVE SHAFT ASSEMBLY (KEYED)
quantity
item description part no. #3 #2
1 #3 (design C splined shaft) 033-91714 1 -
#2 (design C keyed shaft) 033-91710 - 1
2 shaft bearing 230-82214 1 1
3 retaining ring 033-91486 2 2
4 square key 5/16 x 1-1/4 033-71514 - 1
See figure 2. Position the barrel (1) with the bores facing down on a clean surface.
Install holddown spring (3) into barrel counterbore.
Install spring retainer (5) into counterbore and seat against spring.
Install retaining ring (6) into barrel counterbore groove. Make sure retaining ring is fully
engaged in groove.
Position barrel stop (4) over auxiliary drive shaft (2). Turn barrel on side and install
auxiliary drive shaft and barrel stop through barrel spline and holddown spring.
PARTS LIST FOR FIGURE 2 quantity
item description part no. P11 P14
1 barrel & sleeve ass’y (P11) S13-45381 1 -
barrel & sleeve ass’y.(P14 S13-43965 - 1
2 auxiliary drive shaft 033-91053 1 1
3 barrel holddown spring 033-71562 1 1
4 stop 033-71561 1 1
5 spring retainer 033-71560 1 1
6 retaining ring 033-71564 1 1
ASSEMBLY PROCEDURES
10
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item description part no. qty.
1 retaining ring (yellow) .107”-.109”(2.72-2.77mm) 033-71556 1
retaining ring (green) .105”-.107”(2.67-2.72 mm) 033-71557
retaining ring (red) .103”-.105”(2.62-2.67 mm) 033-71558
retaining ring (blue) . 101”-.103”(2.56-02.62 mm) 033-71559
retaining ring (white) .098”-.100”(2.49-2.54 mm) 033-91231
retaining ring service kit S23-12547
2thrust washer 033-91706 1
4 piston & shoe assembly w/retainer P11 S13-45544 1
piston & shoe assembly w/retainer P14 S13-43970
5 creep plate 033-71569 1
6 servo stem 033-71596 1
7 orifice screw 033-20641 2
8 soc. hd. cap screw 359-09240 2
9 button hd. screw 353-25073 2
10 servo plate 033-53874 1
11 hex. hd. screw 1/2-13 x 3”306-40189 4
12 soc. setscrew312-09032 2
13 hex. hd. screw 3/8-16 x 2-3/4”306-40140 4
14R right side chamber cover CW rot. 033-71598 1
right side chamber cover CCW rot. 033-71595
14L left side chamber cover CW rot. 033-71597 1
left side chamber cover CCW rot. 033-71593
15 dowel pin 324-22428 4
16 chamber 033-71615 2
17 steel ball 3/16”H & G. 201-06001 4
18 seal 606-25040 2
19 rocker cradle,“C”design 033-91712 1
20 O-ring 90 S-1 ARP 905 691-00905 2
21 hex socket plug SAE-5 488-35020 2
22 rocker cam S23-12107 1
23 vane spring 033-72233 12
24 hold down vane 033-72234 4
25 vane seal cartridge see below2
25a seal backup plate 033-71608 4
25b vane seal 033-71611 2
25c O-ring 90 S-1 ARP 125 691-00125 2
25d spacer 033-71607 2
25e check valve033-70803 2
26 override tube 033-71609 2
ASSEMBLY PROCEDURES
PARTS LIST FOR FIGURE 3
rocker cam, pistons and retainer
11
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See figure 3. Position the cradle (19) on a clean flat surface with the large flat area
down.
Position the rocker cam (22) on the cradle (19). Note marks made earlier to indicate
top of rocker cam & cradle.
Place O-ring (25c) around spacer (25d) and insert in the vane seal (25b).
Insert check valve (25e) inside of spacer (25d) and assemble between the two backup
plates (25a) with the notched V’s exposed.
Install assembled cartridge in slot in cam as indicated in figure 3. Repeat on opposite
side of cam.
Insert the four holddown vanes (24) and springs (23) in the slots on each side of the
control vanes (25). Note: Install holddown vanes with beveled edge sloping away
from the vane seal cartridges.
Position both control chambers (16) on a clean flat surface with seal grooves turned
up. Drop the four steel balls (17) in the four counterbored holes at each end of the
seal grooves.
Lubricate seals (18) and insert in seal grooves in control chamber (16). Note: The
tapered side of the seals must be pushed into the grooves and the ends must cover
the steel balls.
Install the control chamber (16) with seal (18) and steel balls (17) assembled over the
control vane (25). The seal must be against the cam. Rotate the chamber until it
passes over the control vane assembly, then rotate in the opposite direction until the
dowel pins (15) can be pushed through the chamber (16) and into the cradle (19).
Install chamber in the same manner on the other side of the cam.
Two sets of chamber covers are available. The set marked CW must be installed in
the right hand rotation pump, and the set marked CCW must be used in the left hand
rotation pump. (Rotation is determined facing the pump shaft end). The covers must
be installed with the tubing holes and the tapped holes at the top of the unit. Install
chamber covers (14R) and (14L) on the control chambers (16) over the dowel pins
(15). Referring to the “T”marked on the rocker cam (22) and cradle (19), the tapped
holes must be at the top.
Install two 1/2-13 screws, (11) in each side and torque to 75 ft. lb. (101.7 Nm).
Install two 3/8-16 hex hd. screws (13) in each side and torque to 30 ft. lb. (40.7 Nm).
Install O-ring (20) and plug (21) in each cover.
Install tubes (26) in reamed holes in each cover. These tubes must be a tight fit. If
tubes are loose, the ends can be expanded with a tapered punch. Tap the tubes in
ASSEMBLY PROCEDURES
FIGURE 3
rocker cam assembly
ROCKER CAM ASSEMBLY
12
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place with a plastic mallet.
Install two orifice screws (7) in the servo stem (6). Position the stem on the rocker
cam input side at 9 o’clock position on “B”suffix, or 3 o’clock for “A”suffix models.
Install servo stem on rocker cam using screws (8). Torque to 70 in.-lbs. (7.91 Nm).
Install two #10-24 button hd. screws (9) in the servo plate (10). Install servo plate with
the button hd. screws into the servo stem. Torque the screws to 30 in.-lb. (3.39 Nm).
Install two soc. setscrews (12) in the servo plate (10) and torque to 5 ft.-lb. (6.8 Nm).
Caution: the screws must not protrude above the servo plate.
Install creep plate (5) over center post on rocker cam (22) with small O.D. of plate
turned toward cam.
Position the piston/shoe/retainer assembly (4) over the center post and against the
creep plate. Install bearing (3) and thrust washer (2) over center post of cam and
against the creep plate.
Five different retaining rings (1) are available for the holddown assembly. Each ring is
marked: white dot .099”(2.51 mm) thick, blue dot .102”(2.59 mm) thick, red dot .104”
(2.64 mm) thick, green dot .106”(2.69 mm) thick, and yellow dot .108”(2.74 mm) thick.
Install the thickest ring (1) with the dot up, that will fit in the groove on the center post
and allows a maximum clearance of .002”-.004”(0.051-0.102 mm) between the shoe
and creep plate while grasping one piston and lifting tightly against the shoe retainer.
The piston/shoe/retainer assembly (4) must be free to rotate easily by hand. The
assembly must be rotated through 3600to confirm there is no binding and that each
shoe is always free in the retainer plate. Oil the assembly thoroughly.
See figure 4: Position the cradle and cam assembly with the piston and shoe assem-
bly attached with “T”marked on the cradle turned up.
Install straight thread connectors (3) and O-rings (4) into threaded holes in cradle.
Install right and left hand pressure feed tubes (5 & 6) to connectors (3). Tighten con-
nectors until snug.
Position the mounting flange (9) with the large open end up, and the seal drain port at
the six o’clock position. Install two dowel pins (8) in the cradle mounting surface of the
flange and four locating sleeves (10) in the outer edge of the flange.
Position the rocker cam and cradle assembly over the mounting flange, with the over-
ride tubes at the 3 o’clock position. Install rocker cam and cradle assembly over the
two dowel pins (8) in the mounting flange. Be certain that cradle is seated over the
pins and against the flange.
Position the mounting flange, with the rocker cam assembly installed, on the top or bot-
tom side and install two 3/8-16 screws through the seal retainer area and into the cra-
dle. These screws are required to hold the rocker cam assembly in place and will be
removed later.
Return the assembly to an upright position with the mounting flange down. Tilt the
rocker cam to either extreme position in the cradle.
Position the barrel assembly with auxiliary shaft (1) directly over the pistons. Start with
the uppermost piston and guide them one at a time into the barrel. Return the rocker
cam to a level position in the cradle.
PARTS LIST FOR FIGURE 4
item description part no. qty.
1 barrel and auxiliary shaft assy. see fig. 2 1
2 override pressure tube 033-71609 2
3 connector 492-15265 2
4 O-ring, 90 S-1 ARP 902 691-00902 2
5 tubing assembly (right side) S13-43967 1
6 tubing assembly (left side) S13-43966 1
7 rocker cam and stroking assembly see fig. 3 1
8 dowel pin 324-23216 2
9 mounting flange, design C 033-91711 1
10 locating sleeve 033-72664 4
11 O-ring 90 S-1 ARP 904 691-00904 2
ASSEMBLY PROCEDURES
PISTON/SHOE/RETAINER
ASSEMBLY
MOUNTING FLANGE, CAM &
CRADLE, BARREL & AUX.
SHAFT ASSEMBLY
FIGURE 4
mounting flange, cam & cradle, bar-
rel & aux. shaft assembly
13
12 plug 488-35061 2
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See figure 5: Wash and dry all parts. During assembly, lapped and ground surfaces
should be kept lubricated with clean oil and protected from nicks or surface damage.
Position housing (1) on a clean flat surface with the large open end up.
Clean housing (1) and barrel bearing (2). Apply loctite primer grade “T”and loctite
retaining compound #609 to bearing O.D. and bearing bore of housing. Rest housing
on mounting flange end.
Position notch in bearing (2) in alignment with retainer hole in the housing bore. With
smooth and steady force, press the bearing into the housing bore until seated. DO
NOT HAMMER OR BEAT INTO PLACE. Install bearing retainer (8) with O-ring (7).
Torque to 50 lb. ft. (68 Nm). Place O-ring (5) on plug (6) and install adjacent to bearing
retainer (8).
Turn housing (1) on side and install spring pin (3) in the 1/4”through hole in the control
cover pad. The pin must be 3/8”(9.5 mm) below the pad surface. THE PIN MUST
NOT INTERFERE WITH THE INTERNAL BEARING CAGE. Install two dowel pins (4)
in the blind holes in the same pad. Repeat previous step on the opposite side of the
housing.
PARTS LIST FOR FIGURE 5
S13-43962 housing assembly
item description part no. qty.
1 housing 033-91191 1
2 bearing 033-91190 1
3 spring pin 325-16320 2
4 dowel pin 324-21608 4
5 O-ring 90 S-1 ARP 916 691-00916 1
6 hollow hex plug SAE-16 488-35024 1
7 O-ring 90 S-1 ARP 908 691-00908 1
8 bearing retainer 033-91106 1
See figure 6: Install the three face plate pins (1) in the holes provided in the barrel
face.
Apply heavy grease to the face of the barrel and install the face plate (2) over the pins
(1) in the barrel.
Install gasket (3) over the four locating sleeves (item 10 on figure 4) in the mounting
Position the housing assembly (4) over the barrel and auxiliary shaft assembly and
carefully guide the override tubes and pressure feed tubes (items 2, 5, and 6 on figure
4) through the housing assembly (4).
PARTS LIST FOR FIGURE 6
item description part no. qty.
1 face plate pins 033-49825 3
*2 barrel face plate P11 only 033-71921 1
barrel face plate P14 only 033-71575
3 housing gasket 033-91076 1
4 housing assembly (figure 5) S13-43962 1
5 mtg. flange, cam, barrel assembly see fig. 4 1
*Note: item 2 arcuate port width: P11 = 15/32”(11.9 mm) P14 = 5/8”(15.9 mm)
HOUSING ASSEMBLY
FIGURE 5
housing assembly
PARTS LIST FOR FIGURE 5
HOUSING/END CAP/CAM/
BARREL ASSEMBLY
FIGURE 6
14
CAUTION: Make certain the face plate is properly seated on the barrel and pins with
the steel side towards the barrel face. The face plates have only one side bronzed
and this must be towards the port plate. If necessary, remove coating from edge of
face plate to determine bronze side.
ASSEMBLY PROCEDURES
NOTCH
flange.
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See Figure 7: Position the port block (1) on a clean flat surface with the two open
ports up. THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED.
Position needle bearing (2) on tool (figure T-1) with the marked end of the bearing
against the shoulder on the tool and press the bearing (2) into the port block. The
bearing must be .010”- .025”(0.254 - 0.635 mm) below the surface.
Slip check rings (3) into the two 1.50”ports and align holes in the ring with the side
holes in the port wall. Place lock washers (5) on special screws (4). Insert screws (4)
through port wall and drilled holes in checks (3) and thread into clamps (6). Torque to
10 ft. lb. (13.6 Nm). Thread two check valve assemblies (7) into valve face of port
block.
Place O-rings (9, 11, 13 & 14) on hollow hex plugs (8, 10, 12 & 15) and thread into
tapped holes in port block.
PARTS LIST FOR FIGURE 7
S13-44138 port block assembly
item description part no. qty.
1 port block 033-57912 1
2 needle bearing 230-82146 1
3 check ring 033-70502 2
4 special screw 033-70908 2
5 lock washer #10 348-10016 2
6 clamp 033-70489 2
7 check valve assembly S13-40266 2
8 hollow hex plug, SAE-6 488-35041 6
9 O-ring 70 S-1 ARP 906 691-00906 6
10 hollow hex plug, SAE-4 488-35001 4
11 O-ring 90 S-1 ARP 904 691-00904 4
12 hollow hex plug, SAE-10 488-35055 1
13 O-ring 90 S-1 ARP 910 691-00910 1
14 O-ring 90 S-1 ARP 908 691-00908 2
15 hollow hex plug, SAE-8 488-35018 2
See figure 8: Position the pump with the bearing retainer in the housing assembly at
12 o’clock position.
Install gasket (5) on the housing assembly (6).
Install the two special pins (3) in the face of the port block assembly. Apply petroleum
jelly or heavy grease to the plate (4) and position port plate over the pins (3) on the
port block. Port plate must be fully seated and indexed towards direction of rotation.
Slide the port block assembly and port plate over the end of the auxiliary shaft. Be
certain that tubes 2, 5 and 6 shown on figure 4 are engaged and that the port plate (4)
is still on the pins (3).
When the pump is properly assembled, the valve mounting surface will be at the top of
the unit.
Install the four bolts (1) with washers (7), and torque bolts evenly in 50 ft.lb (68 Nm)
increments to 350 ft. lb. (475 Nm) total.
ASSEMBLY PROCEDURES
PORT BLOCK ASSEMBLY
T-1
FIGURE 7
port block assembly
FIGURE 8
port block/housing assembly
PORT BLOCK/HOUSING
ASSEMBLY
15
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item description part no. qty.
1 hex head cap screw 306-40172 4
2 port block assembly (figure 7) S13-44138 1
3 port plate pins 324-21610 2
4 RH port plate 11 in3 033-71915 1
LH port plate 11 in3 033-71914
RH port plate 14 in3 033-71617
LH port plate 14 in3 033-71600
5 port block gasket 033-91079 1
6 housing/flange assembly figure 6 1
See figure 9: Position the unit with the shaft in a horizontal position and the valve
block mounting surface turned up. Rotate the shaft until the small keyway in the auxil-
iary shaft is at 12 o’clock position.
If pump is being assembled for right hand rotation install dowel pin (8) in hole in port
block at the 9 o’clock position when viewing from port block end of unit, if left hand
pump, install at 3 o’clock position.
Install side plate (1), steel side first, over dowel pin. Insert key (2) in rear keyway on
auxiliary shaft. Install the inner gear of the gerotor assembly (3c) on the shaft and
over the key (2). Install the eccentric ring (3a) on the dowel pin (4). Install the large
outer gear of the gerotor assembly (3b) inside the eccentric ring (3a) and over the
inner gear.
Install center port plate (4) over the auxiliary shaft, engaging the dowel pin (8). The
suction area of the port plate must be located at the bottom of the unit.
Install key (6) in the remaining auxiliary shaft keyway. Install the inner gear, eccentric
ring and large outer gear of the gerotor assembly (7) as before.
Place O-rings (10) and (11) on side plate assembly (9). Lubricate the O-rings and slip
the pressure plate (12) over the O-rings on the side plate assembly. Slip the two
plates over the auxiliary shaft and position the gerotor side plate over the dowel pin
(8).
Place seal ring (15) on auxiliary shaft. Position bearing (14) between the two thrust
washers (13) and install around the seal ring (15). Install insert (19) over splline on
shaft. Thread holddown nut (16) on the shaft and tighten no more than 10 ft. lb. (13.6
Nm) max. Back off the nut (16) until second slot is aligned with pin hole in the shaft.
Insert pin (17) through nut and shaft and secure with ring (18).
Check the main shaft for smooth rotation. If not smooth, check the gerotor parts for
position and holddown nut for proper adjustment.
ASSEMBLY PROCEDURES
PARTS LIST FOR FIGURE 8
port block/housing assembly
GEROTOR AND BARREL
HOLDDOWN ASSEMBLY
16
Note: When changing pump rotation consult parts list for proper side plate assembly
(9).
FIGURE 9
gerotor and barrel holddown
7 washer 350-10109 4
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item description part no. qty.
1 side plate 033-71619 1
2 square key 1/8 x 9/16 211-22034 1
3 gerotor and eccentric ring assy, replenishing. S13-43334 1
4 center port plate S13-43963 1
6 square key 1/8 x 9/16 211-22034 1
7 gerotor and eccentric ring assy, servo. S13-43334 1
8 dowel pin 033-71620 1
*9 side plate & bearing assembly see below 1
10 O-ring 70 S-1 ARP 144 671-00144 1
11 O-ring 70 S-1 ARP 129 671-00129 1
12 pressure plate 033-70531 1
13 thrust washer 350-10081 2
14 bearing 230-82164 1
15 seal ring 033-72101 1
16 holddown nut 033-91052 1
17 pin 033-53921 1
18 retaining ring 033-53923 1
19 insert 033-91051 1
*for RH pumps use S13-46762
*for LH pumps use S13-46763
item description part no. qty.
1 valve block 033-91221 1
2 check valve assembly S13-40266 2
3 orifice plug .047”(1.2 mm) 033-91249 4
4 O-ring 90 S-1 ARP 903 691-00903 3
5 seat 033-70508 1
6 soc. setscrew 5/16-24 x 1 312-13160 1
7 hex nut 5/16-24 335-13100 1
8 housing 033-70545 1
9 O-ring 90 S-1 ARP 910 691-00910 1
10 seal piston 033-21767 1
11 O-ring 70 S-1 ARP 012 671-00012 1
12 spring 032-91798 1
13 cone 033-12288 1
14 servo strainer assembly S13-43240 1
19 O-ring 90 S1 ARP 906 691-00906 1
20 hex plug SAE-6 488-35003 1
21 dowel pin 1/8 x 5/8 324-20810 1
22 O-ring 90 S-1 ARP 904 691-00904 5
23 hollow hex plug SAE-4 488-35001 5
25 plug 488-35049 2
*26 spring pin 3/16 x 3/4 325-12120 2
27 sequence seat 033-70507 2
28 repl. & servo seat 033-70500 4
29 gasket 033-91193 1
30 sequence poppet 033-72378 2
31 servo & dual relief poppet 033-72379 4
32 spring (light weight) 1-9/16”OAL 033-22141 1
33 spring (1-7/16”OAL) 033-70512 2
34 spring retainer 033-70482 1
35 spring (1.09”OAL) 033-71086 3
36 pilot relief assy S23-12813 1
37 O-ring 70 S-1 ARP 050 671-00050 1
42 retainer plate 033-91422 1
43 button hd. screw 10-24 x 3/4 353-25078 4
45 acorn nut 327-25006 1
46 spring pin 1/8x 3/4 325-08120 2
47 O-ring 70 S-1 ARP 013 671-00013 2
48 O-ring 70 S-1 ARP 014 671-00014 2
ASSEMBLY NUMBER S23-12770
SEAL KIT S23-00135
*Not used after 8-96
ASSEMBLY PROCEDURES
PARTS LIST FOR FIGURE 9
gerotor and barrel holddown
PARTS LIST FOR FIGURE 10
valve block assembly
(after 7-93)
17
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Note: Do not use impact tools or over-tighten threaded parts.
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
See figure 10: Place valve block (1) with the six poppet valve bores up in order to
press two spring pins (26) in position. Spring pins to be .12”(3.04 mm) below the sur-
face of valve block. (Not required after 8-96)
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic
stop nut onto the orifice screw and torque to 23 in. lb. (2.6 Nm).
b. Install the strainer support, filter screen, and 6-32 x 1/4 lg. screw. Torque 6-32
screw to 13 in. lb. (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve
block.
Place springs (33), 1.43”(36.3 mm) into outermost bores at each end of the valve
block. Place sequence poppets (30) over these springs. Position seats (27) small
shoulder side first over poppets.
ASSEMBLY PROCEDURES
FIGURE 10
valve block assembly(after 7-93)
VALVE BLOCK ASSEMBLY
(after 7-93)
18
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Place springs (35), 1.09”(27.7 mm) into bores next to the sequence poppet valves.
Place dual relief poppet (31) over these springs. Position seats (28) with the groove
side facing up, over poppets.
Place spring (32) 1.56”(39.6 mm) long, into bore next to compensator valve side of
block. Install replenish poppet over spring. Position seat (28) with the groove side fac-
ing down, over poppet
Carefully position the retainer plate (42) over seats and poppets. Pressing with one
hand on the valve block, compress seats, poppets and springs far enough to alternate-
ly thread two button head cap screws (43) in far enough to hold the retainer plate.
Install the other two screws and alternately tighten screws. Torque to 30 lb. in. (3.39
Nm).
Lubricate O-ring (4) and install onto seat (5). Thread seat into valve block. (Be careful
not to damage bore in seat.) Torque to 15 lb.-ft. (20.3 Nm).
Apply petroleum jelly to shank of cone (13) and install spring (12) on cone. Carefully
insert cone and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11), install in groove of piston (10) and insert end into spring (12).
Install piston in housing guide (8).
Lubricate O-ring (9) and install on housing guide (8) and thread into valve block.
Tighten in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring. Install acorn nut (45) over end of soc. setscrew (6).
Using a small bladed screwdriver, thread the pilot replenishing relief valve assembly
(36) into valve block and lightly tighten in place. (Do not over tighten. Over tightening
can cause sides of slot to break now or at next removal.
Lubricate O-ring (4) and install on plug (25) and tighten plug in place, two places.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tight-
en). Lubricate O-ring (22) and install on plug (23) and tighten in place.
Repeat on other end of valve block.
Lubricate O-ring (19) and install on plug (20) and tighten plug in place.
Install pin (21). Lubricate O-ring (22) and install over plug (23) and tighten in place.
Lubricate two O-rings (22) and install over two plugs (23) and tighten in place.
Using a small hammer, carefully tap spring pins (46) into and through the retainer plate
(42). The pins should bottom out in holes leaving enough length sticking out for pilot-
ing into the port block.
Lubricate O-ring (47), (48), and (37) and install in the bottom of retainer plate (42).
ASSEMBLY PROCEDURES
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Note: Do not use impact tools or over tighten threaded parts.
See figure 11: Wash and dry all parts. During assembly, lapped and ground surfaces
should be kept lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two spring
pins (26) in position. Spring pins to be .12”(3.04 mm) below the surface of valve
block. (Not required after 8-96)
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic
stop nut onto the orifice screw and torque to 23 in. lb. (2.6 Nm).
b. Install the strainer support, filter screen, and 6-32 x 1/4 lg. screw. Torque 6-32
screw to 13 in. lb. (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve
block.
ASSEMBLY PROCEDURES
FIGURE 11
valve block assembly for special
mounting of servovalve (after 7-93)
VALVE BLOCK ASSEMBLY
FOR SPECIAL MOUNTING OF
SERVOVALVE
(after 7-93)
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