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General Reuse and Salvage Guideline For Hydraulic Piston Pumps and Motors
General Reuse and Salvage Guideline For Hydraulic Piston Pumps and Motors
2022/01/26 General Reuse and Salvage Guideline for Hydraulic Piston Pumps and Motors {5058, 5070} (SEBF9307-30)
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Revision History:
Revision Summary of Changes in SEBF9307
Added 20 new serial number prefixes.
30
Updated Tables 2 and 3
26–29 Added new serial number prefixes.
Table 1
Introduction
© 2022 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary
processes therein without permission may be violation of intellectual property law.
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This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and
salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most
current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your
product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is
available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage
techniques and/or methods.
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System
website 2.0 (SIS web 2.0) interface.
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and
warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to
other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this
publication and the warnings that are on the product are not all inclusive. Ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are used. Ensure that the product will not be damaged or made unsafe by any
operation, lubrication, maintenance, or the repair procedures used.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”.
Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.
Illustration 2 g00008666
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Pay Attention!
Become Alert!
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document
and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating
techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also,
determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of
publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar
dealers can supply the most current information.
Safety
Personal injury can result from hydraulic oil pressure and hot
oil.
Make sure all of the attachments have been lowered, oil is cool
before removing any components or lines. Remove the oil filler
cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Summary
The purpose of this document is to give visual guidelines to see if piston pump and motor parts can be used again.
When used in the same application, parts that can be used again can be expected to give normal performance until the next overhaul.
Never install a part that this document shows cannot be used again.
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During reconditioning, correct any conditions that might have caused the original failure.
References
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual (OMM) for
the part or machine of focus before initiating this inspection or procedure.
References
PEGJ0075
PERJ1017
Catalog"
"Dealer Service Tools
Reuse and Salvage Guideline
SEBF8148
SEBF9236
"Fundamentals of High Velocity
Oxygen Fuel (HVOF) Spray for Reconditioning Components"
Reuse and Salvage Guideline
SEBF9238
"Fundamentals of Arc Spray for
Reconditioning Components"
Reuse and Salvage Guideline
SEBF9240
"Fundamentals of Flame Spray
for Reconditioning Components"
Table 2
—
(2)
Clevis/ Shackle
Repositioning
and Movement
Table 3
(1)
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety
(2) standards.
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for specific components.
Optional Tools
Source Description
Lapmaster International (lapmaster.com) Lapping Machine
Sunnen (sunnen.com) Convex Barrel Lap Machine
Table 4
Cleaning Procedure
Before a part is inspected, wash the part in a clean solvent made from petroleum. Wash each part separately. If several parts are washed together,
there is a possibility that the machined surface can be damaged. Use compressed air to dry the part. Put hydraulic oil on the part to prevent rust or
corrosion. Put the part in a clean container. Use a lint-free towel to clean the part before assembly. Be sure to put oil on parts during assembly.
Inspection Procedure
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Piston pump and motor parts have wear patterns that can be seen but not felt by a fingernail or pencil lead after salvage procedure. This type of
wear has no effect on the performance of the part. Unless stated in this guideline, parts cannot be used again that have wear patterns felt with a
fingernail or pencil lead after the salvage procedure. Throughout this guideline, the fingernail or pencil lead inspection will be used to determine if a
part can be used again.
Use 4/0 emery polishing paper. Refer to Tool Catalog, PERJ1017, "Dealer Service Tools Catalog". Put the emery paper on a ground surface plate (
7B-0337 Plate) so the paper is smooth. Do not use any other surfaces.
Wash the part in a clean solvent. Let the part dry at room temperature. Put hydraulic oil on the part and then put the part in a clean container.
1. Wet the emery paper with a clean solvent made of a petroleum base.
2. Place the part on the emery paper with the surface to be "touch lapped" on the paper.
Illustration 3 g02552199
Touch lapping procedure used on a piston slipper face.
3. Move the part in a pattern tracing out a number "8". More than ten complete number "8" patterns is not necessary. Refer to Illustration 3.
4. Wash the part in a clean solvent. Let the part dry at room temperature.
5. Put hydraulic oil on the part, and then put the part into a clean container.
NOTICE
When you handle or put pump and motor parts in storage, care
must be taken to prevent damage to the machined surfaces.
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Illustration 4 g02552218
Apply compound at several points on sealing surface.
Use Grade A silicon carbide lapping compound that is suspended in a paste type lubricant. Clover Compound, Thixogenous-Greasemix, or an
equivalent is recommended. Apply the compound to several locations on the surface that is to be lapped. Refer to Illustration 4.
Illustration 5 g02552236
Place the port plate on top of the barrel assembly in an operating position. Apply firm pressure downward on the port plate while sliding plate back
and forth in a circular motion. At the same time, rotate the barrel assembly. Refer to Illustration 5. After a brief time, the lapping compound will lose
lubricity (lubrication capability) and become dry. At this time, apply more compound.
When the discoloration and light scratches are removed, thoroughly clean the components to remove lapping compound before using again. A
clear solvent is recommended.
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Illustration 6 g02552237
Barrel and port plate after hand lapping.
Lapping machines are easy to operate. However, some general guidelines must be followed.
1. Check the lapping plates periodically, preferably every morning before starting production, to ensure lap plate flatness.
2. Fill the slurry tank with a lapping vehicle. The vehicle is purchased premixed, and a lapping compound should be added to the vehicle at a
rate of 8 oz. per gallon.
3. Run the machine without parts for 4 to 6 minutes allowing the compound to mix evenly in the vehicle.
4. Load the parts to be lapped inside the conditioning rings. The parts should be free to move about within the ring and not packed remaining
stationary.
5. Lapping times will vary according to the severity of the flaw that is to be removed. Minor scratches or warpage can usually be removed within
30 to 60 minutes.
c. Polish the lapped surface, using 600 grit emery paper on a 4/0 polishing stand, until surface reflects light.
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Illustration 7 g02552240
Optical flat.
A monochromatic light source and an optical flat are required to determine flatness. Refer to Illustration 7.
Illustration 8 g02552242
Light band pattern.
Test for flatness by observing the light, emitted from the monochromatic light head, reflecting from the surface being checked, up through the
optical flat. A series of dark bands and light spaces will be projected. Refer to Illustration 8. The dark bands are not light rays, but show where
interference is produced by reflections from the test piece in the optical flat. Inspect the light bands for straightness. If the bands are straight and
parallel, the surface is flat. If the bands are curved, the surface is not flat but may be flat enough for your particular needs.
Illustration 9 g03349220
(1) Piston Actuator
(3) Swashplate
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Illustration 10 g03349242
(1) Piston Shaft
Illustration 11 g03351822
Class sizes of piston sets are identified by the marks engraved on top. Example shown in Illustration 11 is class size II. Refer to Reuse And
Salvage Guidelines, SEBF8113 , "Specifications for L-Series Reusable Hydraulic Pump and Motor Components".
Illustration 12 g03351829
Pintle shaft is matched to a specific piston drive shaft and must not be interchanged with other piston shafts. Refer to Illustration 12.
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Illustration 13 g03351836
Spherical ball is ground to match a specific shaft assembly and cannot be interchanged. Refer to Illustration 13.
Note: Be sure that the lubrication port is not plugged. Use a wire to check the hole.
Illustration 14 g03398342
Piston slipper with shallow grooves on the side of slipper.
Use Again
Illustration 15 g03398371
(1) Bearing Area
(4) Piston
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Note: Polishing marks on the new faces are normal. These marks cannot be felt with a fingernail or pencil lead.
Slipper Face
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, do not use the piston assembly again.
Note: Be sure that the lubrication port in not plugged. Use a wire to check the hole. Refer to Illustration 15.
Illustration 16 g03351926
Piston assembly with scratches to bearing surfaces. Use the "Touch Lapping Procedure"
Use Again - Only if reuse criteria are met.
Illustration 17 g02639836
Piston assembly after touch lapping procedure. Not all scratches and erosion were removed.
Do Not Use Again
Illustration 18 g03354568
Piston assembly with large "pop outs" and metal embedded in bearing area.
Do Not Use Again
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Illustration 19 g03354582
Slipper with smeared face.
Do Not Use Again
Illustration 20 g02653537
Piston assembly with foreign material in the slipper face.
Do Not Use Again
Illustration 21 g03398441
Piston assembly with discoloration on the slipper face. Use the touch lapping process.
Use Again
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Illustration 22 g02640056
No discoloration can be seen on the balance land or bearing area after touch lapping procedure.
Use Again
Illustration 23 g03398617
Piston assembly with fine scratches on the slipper face. Use the touch lapping procedure.
Use Again
Illustration 24 g03398619
Piston assembly after touch lapping procedure. Scratches on the balance land cannot be felt with fingernail or lead pencil.
Use Again
Illustration 25 g03398621
Piston assembly with grooves that are not deep on the side of the slipper.
Use Again
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Illustration 26 g02505556
Piston slipper severely damaged due to cavitation and contamination.
Do Not Use Again
Illustration 27 g02653656
Slipper face with erosion in the balance land.
Do Not Use Again
Illustration 28 g02653699
Slipper face with rolled edge.
Do Not Use Again
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Illustration 29 g02653777
Corners of piston slippers must be square.
Illustration 30 g02653838
Slipper feet should freely rotate.
Illustration 31 g02640796
Measurement of the slipper foot thickness.
Note: The slipper foot thickness of all the pistons from a single pump or motor must be measured.
No pits, scratches, nicks, or indentations are allowed which extend across more than 50% of the width of the sealing land surfaces. "Above the
surface" irregularities are not allowed. Rework by touch or power lapping.
Illustration 32 g02641697
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Illustration 33 g03125140
Check the end play of the piston assembly with a V-block, two other pistons, a dial indicator and a flat plate. Put the piston to be measured in the V
of the V-block on the slipper back faces. Put the dial indicator into position with the pointer on the end of the piston. Refer to Illustration 32. Push
down on the piston and set the dial indicator at zero. Pull up on the piston. Refer to Illustration 33. If the dimension measured is more than the
piston assembly end play allowance, the piston assembly cannot be used again.
Illustration 34 g02713192
(1) Piston Ball
Seizure marks on the piston ball are indications of dirt. Seizure marks on the piston shaft are indications of exceeding the permissible maximum
speed of the motor. If grooves can be felt, the hydraulic fluid may be contaminated. Dull contact points are acceptable.
Illustration 35 g03351940
Ball head with scratches that cannot be felt with a pencil lead or fingernail.
Use Again
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Illustration 36 g02714077
Pistons with slight wear on tapered shaft that cannot be felt with a pencil lead or fingernail.
Use Again
Illustration 37 g03351942
Piston rings with slight wear that cannot be felt with a pencil lead or fingernail.
Use Again
Illustration 38 g03351944
Wear on piston rings (sealing surface) that can be felt with a pencil lead or fingernail.
Do Not Use Again
Illustration 39 g03351947
Broken piston ring.
Do Not Use Again
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Illustration 40 g03289176
Clearance between the piston rings and the piston grooves.
Clearance, measured with a feeler gauge, should not exceed 0.10 mm (0.004 inch). The piston rings, and possibly the piston, must be replaced if
clearance is exceeded.
Wear on the thickness of the piston rings is a result of fine contamination in the hydraulic fluid. In addition to wear on the piston ring, wave-shaped
marks can normally be found on the control surface of the control lens.
Illustration 41 g03351948
Pistons with scratches that can be felt with a fingernail or pencil lead.
Do Not Use Again
Illustration 42 g03351950
Piston with metal flakes or scratches that can be felt with a fingernail or pencil lead.
Do Not Use Again
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Illustration 43 g03355671
Piston assembly with blue discoloration on the piston.
Do Not Use Again
Illustration 44 g03355672
Piston assembly with gray bands on the piston.
Use Again
Illustration 45 g03351952
Piston assembly with discoloration and scratches that cannot be felt with fingernail or lead pencil.
Use Again
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Illustration 46 g03351954
Piston exposed to severe contamination.
Do Not Use Again
Illustration 47 g03355704
Arrow points to a phenolic filler that is loose and chipped around the edge.
Do Not Use Again
Illustration 48 g03355713
An arrow points to a phenolic filler that is loose or protrudes from barrel of piston.
Do Not Use Again
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Illustration 49 g02664358
Piston filler has erosion.
Do Not Use Again
Illustration 50 g03356371
Piston that has lost the slipper.
Do Not Use Again
Center Pin
Illustration 51 g02713158
(1) Spring plate impression on the bottom of the center pin
A spring plate impression does not require replacement of the center pin. However, the impression indicates:
Separation (lift-off) of the barrel from the port plate. Separation can result from insufficient oil supply (cavitation) in reverse mode.
The rotary group was not pulled back against the retaining ring after inserting into the housing.
When fitting the motor to the gear box, the drive shaft was pushed in, thus using up all of the end-play.
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Illustration 52 g02713176
Center pin with scratches on the ball head that cannot be felt with a pencil lead. No grooves, no traces of seizure.
Use Again
Illustration 53 g03356375
Left side of Illustration shows center pin with worn ball head. Right side shows center pin with seized ball head.
Do Not Use Again
Cup Springs
Illustration 54 g02713288
Replace cup springs if wear can be seen. Wear is indicated by polished areas.
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Illustration 55 g02713300
Assemble springs as shown.
Illustration 56 g02545463
No evidence of abrasion and scratching on mating surface for ball retainer.
Use Again
Ball Retainer
A retainer with an edge that can be felt with a fingernail or pencil lead where the contact area ends cannot be used again.
Illustration 57 g02664637
Retainer with normal wear and cannot be felt with fingernail or pencil lead.
Use Again
Illustration 58 g03351956
Retainer with extreme wear.
Do Not Use Again
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Retainers must be free of nicks and scratches on the spherical face. Discoloration or blemishes that cannot be felt with a fingernail or pencil lead
are permitted.
Illustration 59 g02802556
Blemishes indicated by arrow which can be seen but not felt.
Use Again
Illustration 60 g03355718
Splines extend three-quarters of the over-all height of the retainer. Retainer meets the reusability specifications.
Use Again
Illustration 61 g03355726
Retainer chamfer matches the chamfer on the cylinder hub. Retainer meets the reusability specifications.
Use Again
Illustration 62 g03356381
Marks can be seen but not felt with fingernail or pencil lead.
Use Again
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Illustration 63 g02545536
Lapping the shoe retainer to the ball retainer.
To improve the mating surface between the shoe and ball retainers:
Seal Retainer
Illustration 64 g03355745
Markings that can be seen but not felt with a fingernail or pencil lead are acceptable.
Use Again
Wear Plate
Illustration 65 g02645623
Wear plate with groove and wear step in the slipper seal area.
Do Not Use Again
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Illustration 66 g03351964
Wear plate with heat cracks that can be felt with a fingernail or lead pencil.
Do Not Use Again
Illustration 67 g03355754
Wear plate with a scratch across the slipper seat area that can be felt with a fingernail or lead pencil. Wear plates should not be used again without first power lapping to remove
scratches.
Use Again
- After Power Lapping.
Illustration 68 g03351967
Wear plate with smeared surface and corrosion pitting.
Do Not Use Again
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Illustration 69 g03351972
Damage caused by piston that has lost a slipper.
Do Not Use Again
Illustration 70 g03352244
Wear plate that is polished in the slipper seat area.
Use Again
Illustration 71 g03352247
Wear plate with scratches that cannot be felt with a fingernail or lead pencil.
Use Again
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Illustration 72 g03352250
Wear plate with discoloration on the back side.
Use Again
Illustration 73 g03352252
Wear plate with circumferential marks on the back side.
Use Again
Retraction Bearing
Illustration 74 g03356387
Retraction bearing with normal wear on slipper surface that cannot be felt with a fingernail or lead pencil. Use the touch lapping procedure on the bearing before installation.
Use Again
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Illustration 75 g03356393
Retraction bearing with high spots that cannot be felt with a fingernail or lead pencil. Use the touch lapping procedure on the bearing before installation.
Use Again
Retraction Plate
Illustration 76 g02645578
Make sure that the retraction plate is flat. Put the retraction plate on a surface plate. With fingers and thumb, push down on opposite edges and
see if any rocking motion can be felt. If rocking motion can be felt, the plate is not flat and cannot be used again unless made flat by power lapping.
Illustration 77 g03352262
Retraction plate with wear at slipper contact area.
Use Again
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Illustration 78 g03352264
Retraction plate with wear on the outside diameter that can be felt with a fingernail or lead pencil may be salvaged by power lapping.
Use Again - After touch lapping, if plate is flat.
Illustration 79 g02552378
Retraction plate.
Use Again - After
touch lapping, if plate is flat.
Illustration 80 g03352270
This plate shows damage from slipper "lifting". Polished or scored surfaces on the area where the spherical washer rides is not acceptable.
Do Not Use Again
Port Plate
Port Plate Nomenclature and Issues
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Illustration 81 g02711304
(1) Control Surface
Wave-shaped run-in is a result of fine dirt particles in the pressure fluid. A high density of solid matter particles ranging from 5 to 10 microns has
the effect of lapping paste.
If both the port plate and barrel are to be replaced with new parts, then no lapping is necessary. New parts are ground to dimension and are
interchangeable. When new and used parts are paired, the control surface must be lapped together.
Illustration 82 g03349254
(3) Rib
(4) Seal Bands
(5) Thrust Face
(6) Port
Illustration 83 g02711370
Contact surface of the port plate must be flat and level. Inspect the levelness with a straight scale.
Use Again
Note: Use the power lapping procedure on both sides of all port plates that can be used again before plates are installed.
A port plate that has scratches or scored marks that can be felt with a fingernail or pencil lead on the critical surfaces or between the ports cannot
be used again. Port plates that are smeared or galled on the critical surfaces or have blue discoloration cannot be used again. An indication of a
smeared or galled port plate is bronze colored material on the port plate surface.
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Use the touch lapping procedure on port plates that have scratches or score marks that can be seen but cannot be felt.
Note: If a port plate and a bearing plate are exchanged at the same time, then lapping is not necessary. New spare parts are ground to dimension
at the factory and are interchangeable. When matching used parts with new parts, lapping is required.
Illustration 84 g03352273
Port plate that has erosion in the seal band.
Use Again - After power lapping.
Illustration 85 g02645858
Port plate after the power lapping procedure.
Use Again
Illustration 86 g02646097
If power lapping removes scratches between ports and in the seal band.
Use Again
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Illustration 87 g03352275
Port plate with scratches in the seal band and thrust surface that cannot be felt with a fingernail or lead pencil.
Use Again
Illustration 88 g02646189
Port plate with a machine mark in the rib should not be used again without first power lapping.
Use Again - After power lapping.
Illustration 89 g03356396
Port plate with smeared thrust face should not be used again without first power lapping.
Use Again - After power lapping.
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Illustration 90 g03356398
Port plate with discoloration should not be used again without first power lapping.
Use Again - After power lapping.
Illustration 91 g03352278
This port plate has light burn marks and no heat checking. Should not be used again without first power lapping.
Use Again - After power lapping.
Illustration 92 g03352279
Port plate with heavy burn marks and scoring.
Do Not Use Again
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Illustration 93 g03352282
Port plate with light scratches on seal band.
Use Again - After touch lapping.
Illustration 94 g03355792
Port plate with scratches across the seal band that can be felt with a fingernail or lead pencil.
Do Not Use Again
Illustration 95 g03352284
Port plate with discoloration.
Use Again
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Illustration 96 g03352291
Port plate with discoloration on the back side.
Use Again
Illustration 97 g02670177
Port plate is etched in the port seal area.
Do Not Use Again
Illustration 98 g03356400
After touch lapping procedure, port plate was not possible to remove all the discoloration from the critical surfaces on the port plate.
Do Not Use Again
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Illustration 99 g02670399
Port plate with cavitation erosion in the port area.
Do Not Use Again
Visually inspect for cracks at the drive slot and kidneys (port openings).
On all bi-metal bearing plates, in addition to a visual inspection, use penetrant inspection to detect cracks on the bronze surface of the plate.
Note: No steel may be visible through the bronze surface of bimetal port plates.
No pits, scratches, nicks, or indentations are allowed which extend across more than 50% of the width of the sealing land surfaces. "Above the
surface" irregularities are not allowed. Rework by touch or power lapping.
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Use a magnetic particle inspection procedure to detect cracks. Cracks are not allowed on any surface of the part.
Use a new port plate for field repair if the above inspection procedures cannot be exercised. This procedure is to ensure that the port plate is not
cracked or softened.
Scrap valve plates that show smearing or metal transfer on the running surface of the mating bearing plate (barrel assembly surface if a separate
port plate is not used.)
For medium-duty valve plates, use a penetrant inspection to detect cracks on the bronze surface of the part.
Barrel Assembly
Nomenclature and Issues
(3) Splines
(4) Bronze
surface / Thrust surface
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If the barrel and the port plate are both replaced at the same time, then lapping is not necessary. New parts are ground to dimension and are
interchangeable. When matching used parts with new parts, lapping is required.
Abrasives
NOTICE
When using abrasives, limit exposure to skin to avoid irritation.
Avoid inhalation if the abrasive is in the form of powder.
Silicon Carbide and Aluminum Oxide lapping compound are recommended for the abrasives. A medium-fine 500-600 grit (17-14 microns) Silicon
Carbide is desired for pre-lapping. A medium-fine 500-600 grit (17-14 microns) Aluminum Oxide is desired for final lapping. Silicon Carbide will
remove material from the port plate and Aluminum Oxide will help with achieving the desired surface finish. Lapping compound can be obtained in
a paste or a powder. Lapping compound should be mixed with a light oil. Avoid water base compounds. When preparing the compound, obtain a
syrup consistency. The mixture should contain 50% oil.
Surface Examination
The following steps will provide a method to check the barrel and the port plate.
1. Examine the surface of the port plate and barrel. Look for wear if the components are used. Light scratches can be removed by lapping. Use
a sharp pencil to identify any large grooves or imperfections. Parts may need replaced if a pencil cannot easily run over the grooves or
imperfections.
2. Examine the surface roughness of the barrel and port plate. An average roughness of 0.1 µm (3.9 microinches) is acceptable for the port
plate. An average roughness of 0.2 - 0.3 µm (7.8 - 11.8 microinches) is acceptable for the barrel.
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3. Scribe at least three lines using pencil lead from the center of the barrel outward. This procedure will verify the mating of the two parts. See
Illustrations 117 and 118.
4. Center the port plate on the barrel. Rotate the port plate on the barrel. Apply light pressure and make five rotations.
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5. Remove the port plate from the barrel. Check the pencil lead marks. Record the wear pattern. Examine the remaining length of the lead
marks.
Note: 1/3 of the line should remain visible. The line should be located near the center of the barrel. Illustration 119 indicates an unacceptable
barrel. Illustration 120 indicates an acceptable barrel. Start the procedure if any one condition exists.
Initial lapping
1. Apply a light coat of 500-600 grit (17-14 microns) Silicon Carbide lapping compound to the port plate. Place the barrel on the port plate. Refer
to Illustration 121.
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2. Rotate the barrel in a circular motion while moving the barrel around the center of the port plate. The lapping motion should form an eccentric
pattern. Refer to Illustrations 122 and 123. An eccentric pattern is desired so that grooves are not created from a repeated motion. Apply
moderate pressure during lapping. Continue this process for 15 to 20 passes.
Note: The large cross hair indicates the center of the port plate which lies below the barrel. The small cross hair indicates the center of the
barrel on an eccentric path.
3. Clean the barrel and the port plate with a solvent to remove the lapping compound. Repeat Steps 1 through 5 in the "Surface Examination"
section. If the desired result is not achieved, continue lapping. Move to Step 4 once the surface is free from scratches and imperfections.
Note: Step 4 uses the file method for testing hardness. This step is not to be confused with traditional Rockwell testing. Hardness testing files
and instructions can be obtained from a local tool supplier.
4. Perform a hardness test on the port plate using the file method. Use a hardness testing file at 65 Rockwell C. Check the lands that have been
affected by lapping. The part must be replaced if the hardness file scratches the surface. Insome cases, the amount of material removed from
the port plate may be too great to maintain the minimum material harness of 67 Rockwell C. Proceed to the final lapping procedure if the
recommended results were achieved.
Final Lapping
1. Apply a light coat of 500-600 grit (17-14 microns) Aluminum Oxide lapping compound to the port plate. Place the barrel on the port plate.
2. Rotate the barrel in a circular motion while moving the barrel around the center of the port plate in an eccentric pattern. Refer to Illustrations
122 and 123. An eccentric pattern is desired so that grooves are not created from a repeated motion. Apply moderate pressure while lapping.
Continue this process for 15 to 20 passes.
3. Clean the barrel and port plate with a solvent to remove the lapping compound.
4. Apply a light coat of oil to the port plate to prevent corrosion. Place the barrel on the port plate.
Note: Cylinder bores cannot be reworked. Therefore, if there are scratches, grooves, scoring, local indentations, or break-out in the piston stroking
area, further inspection is not needed. The barrel must be replaced. Refer to Illustration 124.
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Dark discoloration on the control surface is not a sign of damage. However, with pittings (lead washouts), dark discolorations are indications of
overheating. Single pittings can be removed with lapping. Interlinked pittings or breakouts and/or cracks along the core borders require
replacement of the barrel.
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1. Wash the barrel assembly and piston in a clean solvent. Use compressed air to dry off the barrel assembly and piston.
2. Put a piston into one of the bores to the maximum depth that the piston will go into the bore during operation.
If no movement or only little side movement can be felt in all of the bores, the barrel assembly can be used again. Refer to Illustration 132.
Note: Use a piston in a new barrel assembly to see how much side movement can be permitted. If necessary, use a dial bore gauge to measure
the bore diameters.
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If no wear can be seen on the barrel assembly splines, the barrel assembly can be used again. If necessary, use two pins and an inside
micrometer to measure the splines (X) as shown in Illustration 134. Put the pins 180° apart in the worn area of the splines. For barrel assemblies
that have an odd number of spline teeth, put the pins in splines as near to 180° apart as possible. Use clay or masking tape to hold the pins in
position. Refer to manufacturer specifications. Refer to Illustrations 133 and 134.
Control Lens
If there is a wave-shaped wear on the control surface of the control lens, then the lens must be replaced. This wear can be felt with a pencil lead
between the kidney-shaped slots.
Wave-shaped run-in is a result of fine dirt particles in the pressure fluid. A high density of solid matter particles smaller than 5 to 10 microns has the
same effect as lapping paste.
If both the control lens and barrel are to be replaced with new parts, then no lapping is necessary. New parts are ground to dimension and are
interchangeable. When used and new parts are paired, the control surfaces must be hand-lapped together.
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Miscellaneous
Drum Seal
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Side Block
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Head Assembly
Note: The surfaces shown in Illustrations 144,145, and 146 can be lapped to a maximum of 0.38 mm (0.015 inch). Metering notches must be
altered accordingly. The bearing must be removed and replaced.
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Bearing Ring
When the drive shaft is assembled, secure the nut on the drive shaft with Loctite. Prior to assembly, the part should be cleaned with 4C-8648
Cleaner (Hydrosolv 4110).
Once threads on the drive shaft are clean, coat the thread with Loctite primer. This primer will improve the holding capability of the Loctite. The
primer also shortens the drying time of the Loctite to approximately 20 minutes.
Finally, coat the male threads of the drive shaft with Loctite 242. The Loctite 242 should be applied only to the area under the nut, not to the
complete length of the thread.
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Cover
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Impeller
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Piston Stops
Swash Housing
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Swashplate
Fixed Swashplates
Both the pump and motor swashplates have contact surfaces that operate against the piston slipper faces. A swashplate whose contact surfaces
has scratches or scored marks that can be felt with a fingernail of pencil lead cannot be used again without power lapping. Use the touch lapping
procedure on a swashplate whose contact surface has scratches or score marks that can be seen but cannot be felt.
A swashplate whose contact surface has been smeared or galled cannot be used again. An indication of a smeared or galled contact surface is
bronze-colored material on the swashplate.
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Hanger
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Check the hanger trunnion bearings for damage or abrasion markings. Replace the bearings if damage is present. Refer to the Service Manual for
the assembly procedure and the correct orientation. Refer to Illustration 177.
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Check the machined surface of the hanger for heat cracks that can be seen and felt with a fingernail or pencil lead. Replace the hanger if damage
is present. Refer to Illustration 177.
Creep Plate
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Use a magnetic particle inspection procedure to detect cracks. Cracks are not allowed on any surface of the part.
Head
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Control Head
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Housing
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All mounting faces including the inlet and outlet port face must be reconditioned to remove all rust and discoloration. No scratches which can be felt
with a pencil lead or fingernail are allowed on the O-ring surface of the inlet and outlet ports. Refer to Illustrations 196 and 197.
Valve Cover
Plate Side
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End Cover
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Bearings
NOTICE
Bearings must always be replaced if removed from the shaft.
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Determine the reusability of the bearing before disassembly. No seizure, depression, or abnormal abrasion is allowed. The bearing must not be
removed from the shaft if the bearing is reusable. If the bearing is removed, a new bearing must be installed. The press fit of the inner race on the
shaft is critical.
Piston
Negative Flow Piston
NOTICE
Do not attempt to remove scratches by polishing and reusing
this part.
Pilot Piston
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Servo Sleeve
Servo Piston
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Actuator Piston
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Use Again - If scratches cannot be felt with fingernail or pencil lead and swage around ball is not damaged.
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Use Again - If actuator piston cylinder has no scratches that can be felt with fingernail or pencil lead.
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Servo Inserts
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Large Piston
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Link-Type Piston
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Cartridge
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Sleeve
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Spool
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Drive Shaft
If the bearing surfaces are damaged, metal spray can be used to build up the worn area and the surface can be machined to a "like new" condition.
If this reconditioning is used and the drive shaft meets all other reusability requirements, the shaft can be used again. oSee a thermal spray Reuse
and Salvage Guideline found in the "References" section at the beginning of this document for more information.
Both splines must meet the minimum dimension of measurement over pins to be used again.
Check for thread damage to the tapped hole in the end of the drive shaft. This threaded hole is needed to pull the rotary group back against the
retaining ring after being assembled in housing . The threaded hole can also be used for drawing the drive element (gear) onto the spline of the
shaft.
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(7) Splines
surface
(12) Socket
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The wear in the shaft seal area shown in Illustration 255 applies to both front and rear shafts. If damage to the seal area is present, metal spray
can be used to restore the surface to a "like new" condition.
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Note: Follow the metal spray manufacturer directions carefully in the application of metal spray to the shaft seal area.
1. Measure the shaft outside diameter at the seal area and the shoulder radius (if present) and make a note of each dimension.
2. Worn or damaged surfaces designated as salvageable by chrome plating can also be salvaged by a metal spray process. Metal spray is an
acceptable method of restoring a surface to the original size. Each step in the procedure is critical in achieving the desired coating bond and
surface finish. See any of the thermal spray Reuse and Salvage Guidelines found in the "References" section at the beginning of this
document for more information.
3. Grind the seal area to the diameter you measured in Step 1. The surface finish must be 0.40 to 0.80 µm (16 to 32 µinch). The wheel radius
must be the same or greater than the shoulder radius measured in Step 1.
Spline Measurement
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If the splines have a visible wear step, the shaft cannot be used again. If necessary, measure the splines. Use two pins placed in the splines 180°
apart. For shafts that have an odd number of spline teeth, put the pins in splines as near to 180° apart as possible. Put rubber bands around the
pins and shaft to keep the pins in place. Refer to Illustrations 273 and 274. Refer to the manufacturer for reusability specifications for the pin
diameter and the use again dimension. Use an outside diameter micrometer to measure across the pins. The crown splines must be measured at
the center of the spline for the correct measurement. If measurement is less than the dimension given by the manufacturer, the shaft cannot be
used again.
PIP-11204243
2022/09/14
22:43:44-05:00
i04805716
Caterpillar:
Confidential Yellow
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