Service Training Student Workbook SEBV0S87 April 1995 CATERPILLAR SELF-STUDY COURSE HYDRAULIC PUMP RECONDITIONING MODULE THREE: PISTON PUMP‘SEBV0587 “3+ ‘Table of Contents 4/95 TABLE OF CONTENTS INTRODUCTION MODULE 3 INSTRUCTIONS. MODULE 3 OBJECTIVES MODULE 3 VIDEO QUESTIONS. 7 GENERAL INFORMATION .....csccesesestse 9 COMPONENT IDENTIFICATION «0.0000 eeceetseee dO COMPONENT IDENTIFICATION REVIEW EXERCISE DISASSEMBLY AND ASSEMBLY PROCEDURES. seve 16 Sauer-Sundstrand Series 90 Pump "Key" Service Points 0.0.0 17 DISASSEMBLY AND ASSEMBLY REVIEW EXERCISE. WAS LAB EXERCISE...... 19 COMPONENT REUSABLLITY ........ 21 Cleaning Procedure Inspection Procedure.. 21 Touch Lapping Procedure... Power Lapping Procedure... SPECIFIC COMPONENT REUSE. ...cssososssnsnnnensen od Slipper Face ... 22 Piston oes . nnn eossnen DD Retraction Plate or Slipper Retainer nd Port Plate... Barrel Assembly... Barrel Assembly Bores Barrel Assembly Splines...SEBV0587 4. Table of Contents 4195 TABLE OF CONTENTS (CONTINUED) SPECIFIC COMPONENT REUSE (continued) Swashplate cen Shafts... 23 Shaft Splines 3 COMPONENT REUSABILITY REVIEW EXERCISE..... eee 24 ANSWERS TO REVIEW EXERCISES 25 ‘Answers to Module 3 Video Questions 25 Answers to Component Identification Review Exercises... 25 Answers to Disassembly and Assembly Review Exercises 226 Answers to Component Reusability Review Exercise....e-e 7 26SEBV0587 “5. Module Three 4995 INTRODUCTION This student workbook is part of the Caterpillar self-study course "Hydraulic Pump Reconditioning." This training material is designed to introduce service technicians to the disassembly and assembly of the Sauer-Sundstrand Series 90 piston pump. Emphasis is placed on component identification, funetion, reuse and salvage of parts. This course is designed to provide a technician with the basic knowledge needed to disassemble this pump, examine and recondition, or replace components and restore a customer's machine to working order This course is not designed to teach pump remanufacturing procedures. That task is left to the remanufacturing facilities. Due to the wide number of manufacturers and suppliers in the hydraulic pump industry, the nomenclature used to described pump components may be different. Keep this fact in mind when servicing any pump. For example, the cylinder block, cylinder barrel or barre! all refer to the same ‘component which houses the pistons and provides chambers for the pistons to produce hydraulic flow. The nomenclature in this training program follows the nomenclature used most commonly in Caterpillar service literature This training package is one of several modules. Each module pertains to a different pump and consists of a video tape and corresponding self-study workbook. The workbook contains review exercises that permit students to monitor their own progress. The current training modules are: Module 1: MANNESMANN-REXROTH A8VO SR/60 This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this piston pump. (Video Tape SEVN3027 and Workbook SEBV0585) Module 2: SAUER-SUNDSTRAND Series 40—M46 This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this piston pump. (Video Tape SEVN3028 and Workbook SEBV0586) Module 3: SAUER-SUNDSTRAND Series 90 This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this piston pump. (Video Tape SEVN3029 and Workbook SEBV0587) Module 4: LINDE BPV Series This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this piston pump. (Video Tape SEVN3030 and Workbook SEBV0589) Module 5: VICKERS PVE and PVH Series ‘This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this piston pump. (Video Tape SEVN3031 and Workbook SEBV0590) Module 6: TYRONE Series 25 Tandem This program introduces the student to the disassembly and assembly procedure, component identification and function, and component reuse for this gear-type pump. (Video Tape SEVN3032 and Workbook SEBV0591)‘SEBV0587 Module Three 4/95 MODULE 3 INSTRUCTIONS To start this self-study program, first read the Module 3 Objectives. The objectives identify the goals to be accomplished in the module. After reading the objectives, read the Video Questions. Being familiar with the video questions makes them easier to answer while viewing the tape. Watch the tape and answer the video questions. This training package is self-paced, so feel free to stop or reverse the tape at any time to clarify a particular "key" point or service procedure. After finishing the tape and video questions, check the answers with the answer key in the back of the workbook. If not satisfied with the score, watch the tape and answer the questions again. Next, read the workbook text, answer the review questions and perform the lab exercise. Check the answers with the answer key in the back of the workbook. If not satisfied with the score, do the exercises again. When satisfied with the score on the exercises, this module is complete. MODULE 3 OBJECTIVES While viewing the Module 3 video tape, answer questions pertaining to the disassembly and assembly process of the Sauer-Sundstrand Series 90 pump. 2. Given the Module 3 video tape and workbook, match each pump component with the correct function or identification during a review exercise. 3. Given the Module 3 video tape and workbook, identify the key points in the disassembly and assembly procedures for the Sauer-Sundstrand Series 90 pump. 4, Given a worksheet listing the components and condition of each component, indicate which ‘components should be replaced, reused or salvaged to recondition a Sauer-Sundstrand Series 90 pump. 5. Given the appropriate service manual, disassemble and assemble the Sauer-Sundstrand Series 90 pump and its components during a lab exercise.SEBV0587 4. ‘Module Three 4195 MODULE 3 VIDEO QUESTIONS Directions: Circle the correct answer for each question while viewing the video tape. Stop or reverse the tape at any time to complete the questions. L 4 ‘Why is it important to have clean pump components and a clean work surface during the pump reconditioning process? a. Clean pump components produce higher flow rates. b. Dirty pump components make the disassembly and assembly process harder. ¢. Dirt and other contaminants can damage the precision made components of the pump. 4. To prevent accidental injury due to dirty, oily components. Which publication can be used as a guide to determine whether pump components can be reused? a, “Disassembly and Assembly, CP-563 (Form KENR1627) b. "Pump and Motor Cl and CS-563 Vibratory Compactors Machine Systems" fication Guide" (Form PEGP2010) "Guideline for Reusable Parts and Salvage Operations" (Form SEBF8032) None of the above. If contamination is visible in the rotating group after removing the displacement control, the pump should be a, replaced with a remanufactured or new pump. b. completely cleaned and returned to service. c. thrown away because it is unusable. 4d, disassembled for parts, Each cartridge-type multi-function valve has the capability to perform four functions in the system, ‘These functions are charge relief, low pressure relief, bypass valve and pressure limiter check valve, byp: a b._ pressure limiter, high pressure relief valve, bypass valve and makeup check valve. c valve, pump destroke valve and high pressure relief. d control relief, pressure limiter, high pressure li iter and bypass valve. If one of the two main gerotor components needs to be replaced, a. they should both be replaced. b. replace that one only. c. the entire pump should be replaced. d._ the entire charge pump should be replaced.‘SEBV0S87 4/95 Module Three 6. Location of the gerotor cover locating pin determines a. charge pump reservoir capacity. b, charge pump pressure, c. charge pump flow rate. d. charge pump rotation. 7. The is responsible for swashplate movement, a. servo piston b. swashplate link c._ valve plate d. slider block _ should be applied to all moving components before installation, a. Heavy weight oil b. Petroleum jelly Clean hydraulic oil d. Silicone grease 9. The valve plate must be installed with the arrows pointing a, to the opposite direction of pump rotation. b. in the same direction noted when disassembled. c. in the opposite direction noted when disassembled. d._away from the displacement control 10. There are multi-function valves on the Sauer- pump. jundstrand Series 90 piston a. five b. four c. three d. twoSEBV0587 Module Three 4195 GENERAL INFORMATION Hydraulic pumps contain many components hydraulic flow. When hydraulic flow meets used to perform many functions. that work together to create, maintain and control restriction, pressure is created. ‘This pressure can be Hydraulic pumps come in many shapes, sizes and types (gear, vane, and piston), and have various purposes. Pumps can be fixed displacement or variable displacement design. Ata constant engine rpm, fixed displacement pumps produce a constant volume of oil flow for each revolution of the pump. Variable displacement pumps produce flow from zero displacement to full displacement or anywhere in between. Variable displacement pumps are more complex and contain more components than fixed displacement pumps. Correct identification of the pump type and model is very important, For example, some pumps can be configured as single or tandem (two separate pumps mounted together in the same unit). ‘The Sauer-Sundstrand Series 90 pump is a variable displacement, axial piston, slipper design. It has a tiltable swashplate to vary the pump displacement, Reversing the direction on the tilt of the swashplate 's the flow of oil from the pump. revers Depending on the application, this pump can be controlled by either a mechanical, hydra electrical input signal. ae A Figure 1. Sauer-Sundstrand Series 90 Piston Pump Components,SEBV0S87 -10- Module Three 4195 COMPONENT IDENTIFICATION Charge Pump: In a closed loop hydraulic system, the charge pump provides the initial fill for the system during start-up, supplies cool oil into the low pressure side of the loop to make up for normal leakage, and can supply fluid to operate the controls. <-> co, BS ait Figure 2. Charge Pump Multi-function Valve: Incorporates the makeup check valve, pressure limiter valve, high pressure relief valve and the bypass valve into one multi-function valve cartridge. Makeup Check Valve: When operating in the low pressure (or return) portion of the hydraulic circuit, the multi-function valve operates as normal leakage occurs. makeup check valve to replenish flow losses as Pressure Limiter: When operating in the high pressure (or drive) portion of the hydraulic circuit, the multi-function valve serves as a pressure limiter to destroke the pump as the system pressure increases to maximum. High Pressure Relief Valve: The high pressure relief valve is part of the multi-function valve cartridge and protects the main pump and the hydraulic system from damage due to high system pressure by dumping high pressure oil from the drive side of the loop to the return side of the loop.SEBV0587 Me Module Three 4195 Bypass Valve: When open, the bypass valve connects both sides of the pump and motor circuit and allows the motor to turn with no effect on the pump. This function is used when towing a machine. This valve must be fully closed for normal operation. Figure 3. Multi-function Valve Piston: ‘The component in the rotating group of the pump that receives oil from the low pressure side of the closed loop and delivers the oil flow to the high pressure side of the closed loop. Pg oy | eg Figure 4. PistonSEBV0587 -R- Module Three 4195 ipper: ‘The component in the rotating group that rides with the swashplate and is connected to the piston. A thin film of oil separates the slipper from the face of the swashplate. Figure 5. Slipper Swashplate: The component inside the pump that controls the stroke of the pistons. An increase or decrease in the pump output volume is accomplished by changing the angle of the swashplate. oo —r——~——— ee _. .- Figure 6. SwashplateSEBV0587 -1Be Module Three 419: Servo Piston: The control device that moves the swashplate to increase or decrease the volume of oil flow. The displacement control signal determines which end of the servo piston is pressurized to move the swashplate, Figure 7. Servo Piston Charge Relief Valve: Limits the maximum pressure in the system when the pump swashplate is at zero angle with no output flow from the piston pump. Pe eae 4 ee ee 2 ~~ eer 9 ogee Se aaa? = o 2% oe I & nes pa _ tg ™S oad DT ae Figure 8. Charge Relief ValveSEBV0587 14 Module Three 4/95 Displacement Control: Controls the angle of the swashplate subject to system demands by pressurizing one end of the servo piston, which moves the swashplate, causing the pump to upstroke or destroke as needed. The control operation can be manual, hydraulic or electric. Displacement Control Screen Filters oil entering the displacement control. Figure 9. Displacement Control Swashplate Leveler Springs: Keep the swashplate at 0 degrees when the pump control is in the neutral position or when the system is not operating. During operation, the springs also help to dampen (smooth) the movement of the swashplate. Figure 10. Swashplate Leveler Springs‘SEBV0S87 Ina closed loop hydraulic system, provides the initial fill for the system, suppli -15- Module Three COMPONENT IDENTIFICATION REVIEW EXERCISE Match the component to the correct statement below. Servo Piston F. _ Displacement Control Screen Slipper G. _ Swashplate Charge Relief Valve H. Multi-function Valve Charge Pump 1. Piston Displacement Control J. Swashplate Leveler Springs cool oil into the low pressure side of the loop, and can supply fluid to operate the controls, Incorporates the makeup check valve, pressure limiter valve, high pressure relief valve and the bypass valve. The component in the rotating group of the pump that receives oil from the low pressure re side of the closed side of the closed loop and delivers the oil flow to the high pre: loop. The component in the rotating group that rides with the swashplate and is connected to the piston. The component inside the pump that controls the stroke of the pistons to produce an increase or decrease in the pump output volume. The control device that moves the swashplate to increase or decrease the volume of oil flow in conjunction with the displacement control ignal. Limits the maximum pressure in the system when the pump swashplate is at zero angle. Controls the angle of the swashplate subject to system demands. The control operation can be manual, hydraulic or electrical. Keeps the swashplate at 0 degrees when the pump control is in the neutral position or when the system is not operating. 4/95 Directions: A. B. CG D. E. 1. 2 3. 4, 5, 6. 72 8 9 10. Filters oil entering the displacement control.SEBV0587 -16- Module Three 4195 DISASSEMBLY AND ASSEMBLY PROCEDUR' Later in this program a Sauer-Sundstrand Series 90 pump will be disassembled and assembled as a lab exercise. These are some "key" points that must be observed during the disassembly and assembly procedures. Dirt and other contaminants can damage the precision made components of the pump. All disassembly and assembly procedures must be performed on a clean work surface. Clean all exterior pump surfaces before the disassembly process. Clean all the interior components in clean solvent and dry them with compressed air. After disassembly, check the condition of all components and refer to the "Guideline For Reusable Parts and Salvage Operations, Piston Pumps and Motors" (Form SEBF8032) to determine the reusability of the components. More information on this subject is listed under the heading “Component Reusability” later in this workbook In some cases it may not be economical or practical to recondition a pump. This determination is made after disassembly and close inspection of the pump components. Due to damage or wear to the pump components, reconditioning may not be possible. If the cost to recondition a pump exceeds the cost of a remanufactured unit, the pump should be replaced with a remanufactured unit instead of being reconditioned. Contamination of the hydraulic system may also determine whether a pump should be reconditioned or replaced. If contamination is found after removal of the first few pump components such as covers or controls, it may be practical to stop there and recommend a remanufactured pump replacement and hydraulic system cleaning, ‘This pump contains many small components that need to be marked for proper assembly. Placing a ‘component in the wrong position could seriously damage a pump or cause poor performance. Mark all components for proper assembly. Pump rotation should be identified for proper assembly. In some cases, component orientation determines pump rotation. For example, on a pump equipped with an integral charge pump, the pin in the gerotor ring or cover determines the pump input shaft rotation. The pin in the gerotor ring or cover should be closest to the control for clockwise (CW) input rotation, and away from the control for counterclockwise (CCW) input rotation Certain pump components should always be replaced when reconditioning a pump. O-rings, gaskets and seals should always be replaced. Even if an old o-ring looks reusable, it may not have the sealing properties needed to prevent a leak. A reconditioning job should not be compromised because of a low-cost component such as an o-ring or gasketSEBV0S87 -17- Module Three 4195 Another service item to watch for is matched components. In the case of a gerotor-type charge pump, if one component of the gerotor assembly needs to be replaced, they must both be replaced. ‘These components are matched and create a wear-in pattem as they run. Replacing a single component in a matched set will cause noisy operation, Components that are critical to pump operation include the Charge Relief Valve and the Multi- function Valve. These components must be inspected for wear. A wor component may fail to function properly, causing poor pump performance or damage to other pump components. A close inspection of all components during disassembly is important. Sauer-Sundstrand Series 90 Pump "Key" Service Points The following are some of the "key" service points for the Sauer-Sundstrand Series 90 pump: + Ifa charge pump is installed that has a different displacement from the of eccentric ring and port plates must be changed. inal pump, the gerotor, + Always check and use the correct keyway in the charge pump shaft. + Always clean the internal screens of the displacement control no matter how they look. + Ifthe pump is equipped with dual swashplate leveler springs, be sure the spacer washers are installed. + Always mark the location of the servo piston cylinder cups. + Check for scratches or rolled edges on the slipper face. Touch or power lap the surface, or replace the assembly as required. Refer to the "Guideline For Reusable Parts and Salvage Operations, Piston Pumps and Motors" (Form SEBF8032) as a guide for determining the reusability of the components. + Check the end play between the slipper and the piston. The slipper can feel loose or tight, but must move in all directions without binding. If binding is felt or end play is out of specifications, replace the assembly. + Always install new journal bearings if a new swashplate is used. + The bolts connecting the feedback link to the swashplate have a special locking patch; if reused, follow the correct cleaning procedures and install a suitable retaining compound. + The location of the pressure limiter plugs MUST be verified.‘SEBV0S87 218+ Module Three 4/95 DISASSEMBLY AND ASSEMBLY REVIEW EXERCISE During or after the disassembly and assembly lab exercise, respond to the following statements by indicating T for True or F for False. ——— _. The disassembly and assembly process must be performed on a clean work surface to prevent contamination of the pump components. _—_— 2. The "Pump and Motor Classification Guide" (Form PEGP2010) can be used as a guide to determine the reusability of pump components. ——— __ 3. If binding is felt between a piston and its slipper, the entire assembly should be replaced. —— 4. Even if an old o-ring looks reusable, it should be replaced. —— 5. Insome cases, it may not be economical or practical to recondition a pump. ——— 6. Pump rotation does not make any difference when reconditioning a pump. ——— 7. Matched components such as gerotors should always be replaced as sets. ——— 8. Ifanew swashplate is installed in the pump, new journal bearings must be installed. ——— 9. Locking bolts used on the feedback link to the swashplate may be reused without any special precautions, ——— 10. Ifpiston-to-slipper end play is out of specification, the component may be salvaged and reused.SEBV0587 -19- Module Three 4195 LAB EXERCISE 1. Locate the appropriate service manual and a serviceable Sauer-Sundstrand Series 90 piston pump. Disassemble the pump and its components. 2. After disassembling the pump, complete the component reusability review exercise in this workbook. 3. Using the "Guide for Reusable Parts and Salvage Operations, Piston Pumps and Motors" (Form SEBF8032), determine if it is economically feasible to recondition this pump. Indicate whether the pump should be reconditioned. If not, indicate why. ‘What is the recommended course of action for this pump?‘SEBV0S87 = 20+ ‘Module Three 4/95 NOTES‘SEBV0587 4/95 Module Three COMPONENT REUSABILITY Before it can be determined if a component can be reused, a thorough cleaning and inspection of the component must be made. The following procedures are just the basics. For further information, refer to the "Guideline for Reusable Parts and Salvage Operations, Piston Pumps and Motors" (Form SEBF8032) and the "Guideline for Reusable Parts, Specifications for Reusable Piston Pump and Motor Components” (Form SEBF8033). Cleaning Procedure Before a component is inspected, wash it in a clean, petroleum-based solvent. Wash each component separately. If several components are washed together, a machined surface on one or all of the components could become damaged. Use compressed air to dry the component. Place clean hydraulic oil on the part to prevent rust or corrosion, Put the component in a clean container. Use a lint free towel to clean the component before assembly. Inspection Procedure Piston pump and motor components have normal wear patterns that can be seen but cannot be felt with a fingernail or lead pencil after a salvage procedure. This type of wear has no effect on the performance of the component. In general, components that have wear patterns that can be felt with a fingernail or lead pencil after a salvage procedure cannot be used again, Touch Lapping Procedure Touch lapping is used on certain components so that they may be used again. Touch lapping will not give a component a "like new" surface or surface flatness. It is used only to remove discoloration and very small surface marks. Use 4/0 emery polishing paper manufactured by 3M™ or the Norton Co. or equivalent. Put the emery paper on a ground surface plate (7B0337 Plate) so the paper is smooth. Do not use any other surfaces as they may not be truly flat. Wet the emery paper with clean petroleum-based solvent. Place the surface of the component to be touch lapped on the paper. Move the component in a "figure eight" (8) pattern. About ten complete figure eight’s should be all that is necessary to touch lap the component. If the touch lapping procedure successfully salvages the component, wash the component in clean solvent and let the component dry at room temperature. Put clean hydraulic oil on the component and place in a clean container. Power Lapping Procedure Power lapping can remove wear patterns and surface scratches from components, providing a "near new" surface flatness. Power lapping can produce lap flat surfaces within tolerances of one light band (,00295 mm or .000116 in.). Consistent surface finishes with absolute uniformity are easily attained. Lapping times will vary according to the severity of the flaw to be removed. Always follow the manufacturer’s instructions when using a power lapping machine.SEBV0587 “2 Module Three 4195 SPECIFIC COMPONENT REUSE Slipper Face A slipper face that has light scratches, foreign material or deep scratches in the balance land that can be felt with a fingernail or lead pencil can be used again if the salvage procedures are followed and the reuse criteria is met. Be sure to check the lubrication port on the slipper face. Use a wire to check that the port is not plugged. Fine scratches or discoloration can be removed using the touch lapping, procedure. A slipper assembly with grooves on the side of the slipper may be used again. Check to see if the slipper will move by hand on the piston ball. The slipper can feel loose or tight, but must move in all directions without binding. If binding is felt, the assembly must be replaced. Piston Piston assemblies with blue discoloration on the sides of the piston should not be used again. Piston assemblies with grey bands, light discoloration or scratches that cannot be felt with a fingernail or lead pencil can be used again, Retraction Plate or Slipper Retainer ‘A retraction plate with wear around the slipper holes that can be felt with a fingernail or lead pencil may be salvaged by power lapping. If the plate is checked and found to be flat, it may be turned over and used again without any salvage procedure. Wear on the outside diameter of the plate that can be felt with a fingernail or lead pencil may be salvaged by power lapping. Check the retraction plate for flatness using a 7B0337 Plate. Place the retraction plate on the flat surface and check to see if there is any rocking motion. If not flat, the retraction plate cannot be used again unless it is made flat by grinding, Port Plate A port plate that has erosion in the seal band can be used again provided the plate is power lapped and that the erosion is not across more than half of the seal band. Port plates with scratches between the ports and in the seal band can be used again provided power lapping removes the scratches. A port plate with scratches in the seal band and on the thrust surface that cannot be felt with a fingemail or lead pencil can be used again. A port plate with scratches in the seal band that can be felt with a fingernail or lead pencil can be used again after power lapping if reuse criteria is met. Port plates with machine marks in the rib, smeared thrust faces and plates with discoloration on either side can be used again after power lapping if the reuse specifications are met.SEBV0S87 B. Module Three 4/95 Barrel Assembly A barrel assembly with corrosion and scratches across the seal band that cannot be removed by the power lapping procedure cannot be used again. Barrels with heat cracks in the thrust surface cannot be used again. If the barrel has a wear step in the seal band and the step can be removed using the power lapping procedure, the barrel can be used again. Barrel assemblies with a polished surface, no wear step in the seal band and thrust surface, discoloration and scratches that cannot be felt with a fingernail or lead pencil can be used again. A barrel with a smeared thrust surface can be used again after touch or power lapping. Barrel Assembly Bores Barrel bores must be checked for side movement of the piston in the bore. Use the procedure in the reusability guide to determine if the barrel bores are within acceptable specifications. Barrel Assembly Splines Tf no wear can be seen on the barrel assembly splines, the barrel assembly can be used again. If the splines show signs of wear, follow the procedure in the reusability guide to determine if the barrel can be used again. Swashplate ‘The swashplate can be used again if it has discoloration or polishing on the wear plate surface. If deep grooves or scratches are present on the wear plate surface, the swashplate cannot be used again. A swashplate with light scratches or marks that cannot be felt with a fingernail or lead pencil on the bearing contact areas can be used again. If fretting on the bearing contact area can be felt with a fingernail or lead pencil, the swashplate cannot be used again. Shafts wear marks in the seal surfaces that cannot be felt with a fingernail or lead pencil can be used again. A shaft with chips but no cracks in the keyway can be used again. Shaft Splines Shafts with wear on the splines but no wear steps can be used again. Shafts with wear steps on the splines cannot be used again.SEBV0S87 4195 24 Module Three COMPONENT REUSABILITY REVIEW EXERCISE Directions: Place a letter from the key below that best describes the course of action that should be taken for the condition of the component described in each statement, U= Use Again R= Replace SU = Salvage and Use Again 1 2. 10. ul 18. 19. 20. Piston mbly with blue discoloration on the piston. Slipper assembly with grooves on the side of the slipper. Piston and slipper assembly with binding felt during movement of the slipper. Port plate with scratches between the ports, Piston with scratches that cannot be felt with a fingemail or lead pencil Slipper face with deep scratches in the balance land. Pump shaft with wear steps on the splines. Barrel with a smeared thrust surface. Retraction plate with wear around the slipper holes. Shaft spline with normal wear but no wear steps. Barrel assembly splines with no visible wear Shaft with wear marks in the seal surface that cannot be felt with a fingernail or lead pencil ‘Swashplate with fretting on the bearing contact area. Swashplate with deep grooves on the wear plate surface. Port plate with scratches in the seal band that can be felt with a fingernail or lead pencil. Piston assembly with grey bands. Port plate with erosion across more than half of the seal band after power lapping. Retraction plate that is not flat. ‘Swashplate with polishing on the wear plate surface. Barrel with a wear step in the seal band.4/95 ANSWERS TO REVIEW EXERCISES Answers to Module 3 Video Questions Seren aneyne vwparorwrana Answers to Component Identification Review Exercises L 2, 3, 4. 5, 6, 1, momaraw-~my Module ThreeSEBV0587 -26- Module Three 4195 Answers to Disassembly and Assembly Review Exercises 1. eer ANE ED Homan atsa = 10. Answers to Component Reusability Review Exercise LOR 20 U 3. OR 4. SU 5. U 6. SU 7.°R 8 SU 9 U 10. U WU 12° «2U 1B. OR 14. R 15. SU 16. -U In OR 18, OR 19. U 20. SUCATERPILLAR SEBV0587 Printed in U.S.A 495